Lessons I learned on TOD with CIS removal in the car

[mike sampsel]

With much help from many on this forum,
I managed to fix my TOD leaks with engine in the car.
I removed my CIS at the runner/manifold bolts with engine installed and got much needed help from folks on this forum. Many thanks ...

I made two early big mistakes; first, was overlooking the nut which bolts the airbox to the throttle linkage plate (made lifting the CIS off the runner bolts a real challenge ).
Second, I neglected to appropriately remove the throttle spring (from runner number 2) and I never got a good look at it as it went flying. It managed to wedge itself behind the drivers side shock tower in some dilapidated goop from the sound deadener of way back.


Having the right tools made a huge difference. I ordered the sockets with built in swivels (1/4" and these are the cat's meow for the install of the manifold nuts. Doing it with 1/4" socket and a u-joint instead was the other end of the cat's anatomy!

Because I had no convenient place for my engine and did not have the appropriate tools I chose the CIS removal method instead of engine removal method.

So here is the before and after photos of the TOD.
Before this endeavor:



After the remove/install and some running ...




I applied loctite 574 above the o-ring of the thermostat. Seems the leak from my breather hose is corrected!
Much help from Flat6 (Bruce) on the 574 use.
Also applied some JB weld onto the oil pressure idiot light (green light switch) per Tony.

The case defect still leaked on me after this and because it pushed oil up from the JB weld I thought it might be something else. Anyway, I replaced my stick type JB weld with the epoxy type and now the area is dry as a bone.

Stick type:


Epoxy type, which so far is dry as a bone.




After all this I still have some leakage/oozing which collects/drips off the metal nub in the red circle below. Thinking this might be from the rocker seals? Maybe its a loose head stud?




Hoping the engine stays this clean for a while.