3.0 SC takes WAY too many cranks to Start When Cold

[Gunter]

Some Duct Tape should fix that.

Wow! Looks like prying with a screwdriver made the hole?

Go over everything. It's a good time to check all hoses and replace the usual suspects on top of the engine.

When you're finished and all is well, you'll appreciate the CIS as very reliable.
No more cursing the 30-year old system.

Isn't it amazing that the CIS still worked with that hole?

[oneblueyedog]

It sure is amazing. I noticed that the each runner had a gummy soft spot. This hole was at the bottom and I could not see it. I was in denial about hearing it though. My son actually picked some of the rubber away, but it did rush and whistle.

Maybe the rubber gets soft from Ethanol mix sitting in a puddle. Or maybe this boot was defective. This boot is about 9 years old.

[Gunter]

My experience: I found it easiest to assemble the CIS completely on the bench (Or a sheet of plywood on saw-horses) for several reasons.

It's easier to install the boots so the intake runners sit almost in the correct position.
The clamp-screws can interfer with each other and complete assembly helps to avoid that.
Then the whole CIS can be installed sitting on the runners and the 2 supports.

Clean the mating surfaces for the intakes carefully without dropping anything into the engine; small rags in the holes help.

The new boots offer resistance during re-assembly and the runners need to be manipulated somewhat to make the studs. A very long extension on a 13 mm swivel-socket will reach some of the more difficult nuts.

[oneblueyedog]

I now can't wait for a cold snap. I can't recall when my engine, warmup and town running has been better. Just an amazing difference.

For FI removal I did it the hard way not dropping the engine. Yes it can be done. I takes a lot of component removal and reinstall. I keyed off a prior search. The parts that broke me down were the AUX air device (round can) and tightening the #6 intake runner sleeve and manifold bolts. I made a lot of use of my wife's hand mirror.

I first loosely installed #5 and #6, added the airbox with injectors zip tied. Removed AC compressor and laid it over fender to add #4. Tightened the runner sleeves then tightened the runners. Installed the warm up air pipes, then the AUX air device, AAV and injectors.

#1,2,3 had a trick. I slipped the runners over the machined step so I could set them down flat against the heads. I loosely bolted them, then I slipped the runners back over to the airbox and added and tightened the clamps. Trick is to use silicone grease (but not if you have an 02 sensor) And nudge them back. Tried it because of the 914's I used to have, the boots would just slip over the runner and airbox. I then bolted back the easy stuff.

Bring on the arctic blast! Thanks for the support Gunter!