from the RAVE in one place (page 448 of 1529 in D2 shop manuals, could not find a page in D1 or overhaul)

7. Position inlet manifold to engine. Fit manifold
bolts and, working in the sequence shown,
tighten bolts initially to 10 Nm (7 lbf.ft) then to
51 Nm (38 lbf.ft).

From RAVE in another place: (overhaul for 4.0 engines, page 16 of 82)

3/8 UNC and UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm 30 lbf.ft [lhscouts is on the money as usual]

I agree I done bad, but where else in the manual have I missed? And are not the non-SAI heads on a D2 essentially equal to a D1? Seems like there would be a more detailed drawing in the D1 or overhaul manual for bolt sequence for intake. Maybe I didn't see that page?

Does this mean owners trying to follow the book on a D2 may be in line for the same issue?

Pix of page I printed out, but I can't find the exact one again, not sure where it came from. Says Overhaul in bottom corner.

I thought the puckered up valley pan gasket was keeping things from tightening up as it collapsed. Wrong, so wrong.

 

Wow, this is starting to sound sort of ugly. You don't think it is possible that the manifold bolts are bottoming out ?

 

No, without the manifold in place they will screw all the way flush.

Ugly? Maybe, since this weekend I have also hit two animals in the Mercedes and taken out a head light; someone hit my mail box (bought new one and dug out old concrete and poured more); mower deck wheel came off John Deere and is hiding out with Elvis; and this with the Rover. And SWMBO is federal, so she is on furlough (thanks to elected officials). Probably not a good time to buy a lottery ticket.....

 

Fuel System, Repair, Intake Manifold.
38Nm on the intake bolts, 18Nm on the clamp bolts.
Sorry Savannah.

 

Which shop manual? Page Nnumber? can't find it under SFI fuel system?

 

I don't recall and I'm not at home now. It was a copy of the RAVE of CD I have. You should be able to search "intake manifold". It should only return about 3 results.

 

Page 262 in shop manual - under the MFI section. So I wonder what is different about a D2 head that it would be 51 nm? Different aluminum alloy? Inserts? Different size bolts?

 

Maybe it's a mistake. I remember finding some other item where torque specs were different in the list at the front of the chapter than in the text of the repair.

 

This is in the repair text, in a couple of places. Since D2's have plenty of HG work, this could be an issue.

 

It says 51 in the torque specs at the front too. I wonder if they increased it because of the issues with the bolts getting loose.