How to install a intake on a big block chevy corvette

run a pressure test on the cooling system then pull plugs to see which one or more could be wet and do compression test

IF you clean the head and block properly then the head gasket will have its own sealer in the gasket. The secret is to torque the head bolts down in the correct sequence . I do head tensions in 4 stages and this gives the gasket a chance to even out under the head

To install:

1. Clean all gasket surfaces completely.
2. Install the intake manifold gaskets with the port blocking plates facing the rear of the engine. Factory gaskets should have the words "This Side Up" visible.
3. Apply gasket sealer to the front and rear sealing surfaces of the engine block.
4. Apply a 0.197 inch (5mm) bead of RTV sealer to the front and rear of the block. Extend the sealer approximately 1 / 2 -inch (13mm) onto the heads.
5. Install the lower intake manifold.
6. Apply sealer to the lower intake manifold bolts prior to installation.
7. Install the bolts and tighten in sequence and in 3 steps as follows:
   1. First step to 26 inch lbs. (3 Nm).
   2. Second step to 106 inch lbs. (12 Nm).
   3. Final step to 11 ft. lbs. (15 Nm).
   
   
8. If removed, install the alternator bracket bolt.
9. Install the coolant by-pass hose.
10. Install the EGR valve.
11. Connect the upper radiator hose to the thermostat housing.
12. Connect the heater hose to the lower intake manifold.
13. Connect the fuel pressure and return lines to the lower intake manifold.
14. Connect the wiring harnesses and brackets to the lower manifold.
15. Install the throttle cable bracket, then attach the throttle cable and the cruise control cable (if equipped).
16. Install the transmission oil level indicator and tube, if equipped.
17. Install the EGR tube, clamp and bolt.
18. Install the PCV valve and hose.
19. Install the A/C compressor and bracket.
20. Install the distributor.
21. Install the upper intake manifold.
22. Fill the cooling system.
23. Connect the negative battery cable.
24. Start the vehicle and check the ignition timing (not adjustable).
25. Verify no oil, coolant, vacuum or fuel leaks.

    

26. Install the intake manifold bolts and tighten them to 35 ft. lbs. (48 Nm) in the sequence shown.
    

Buy a gasket kit for the upper end. Remove the valve cover intake and exhaust manifolds. Remove the head bolts. Remove head and clean up block from old gasket material. Take the head to a machinist and make sure that it is not warped. If it is warped either replace the head with a new one or have it machined true. Install new gasket and get torque specs with new head bolts and follow torque sequence using the correct torque specs. Clean exhaust, intake and valve cover of old gaskets. install new gaskets and torque according to specifications.

Cylinder Head Removal & Installation 3.1L Engine To Remove:
NOTE: With some minor variations, this procedure can be used on both the left and right cylinder heads.

1. Raise and safely support the vehicle.
2. Drain the engine coolant and the engine oil. Lower the vehicle.
3. Remove the upper and lower intake manifolds.
4. Remove the rocker arms and pushrods.
5. Remove the exhaust crossover pipe.
6. Remove the engine mount strut bracket.
7. If removing the left side (front) head, remove the dipstick tube.
8. Tag for identification, then remove the spark plug wires.
9. Remove the spark plugs.
10. Remove the exhaust manifold using the procedures found in this section.
11. Remove the eight cylinder head bolts, then remove the cylinder head. There are locator pins that align the head to the block. Pull upwards on the head to disengage the pins, then remove the cylinder head to a suitable work area.
12. If the head is be overhauled, remove any remaining components such as the engine lift hook, the fuel line bracket bolts, the engine coolant temperature sensor, etc., as required.

Position a new gasket, install the head, then tighten the bolts in the sequence shown (3.1L engine shown)

To Install:
NOTE: If the head gasket failed, determine the cause. Gasket failure is caused by the following conditions: improper installation; overheating due to a failure in the electric cooling fan system or a leak in the cooling system; loose or warped cylinder head; missing, off location or not fully seated locator dowel pins; low torque on the cylinder head bolts; warped block surface; scratched or gouged gasket surfaces; excessive intake manifold torque and even cracked engine block tapped holes.

1. Clean all parts well. Remove all foreign material to the bare metal. Do not use a motorized wire brush on any gasket sealing surface. It is good practice to use the proper size thread-cutting tap to clean the threaded bolt holes in the block. This helps assure an accurate torque reading.
2. Place a new head gasket on the clean engine block deck surface. Many gaskets will have some sort of marking denoting TOP or THIS SIDE UP. Make sure the gasket sits flat and is not hung up on the locator dowel pins. Use no sealer on the head gasket.
3. Carefully set the cylinder head in place, using care not to damage the gasket. Make certain that the head engages the locator dowel pins that properly position the head.
4. The bolts should be very clean since dirt built-up on the bolt threads makes it difficult to get an accurate torque reading. These are 'torque to yield' bolts which stretch a small amount when tightened; new bolts are always recommended. On a used vehicle, especially a high-mileage vehicle, it may be difficult to determine if the heads have been removed before and how many cycles the bolts have been removed and tightened. New bolts should be part of any cylinder head service. Use GM Sealer #1052080, or equivalent, on the threads of the head bolts and install all eight bolts, finger-tight.
5. With an accurate torque wrench, tighten the bolts gradually, in sequence, working from the center outwards. Final torque should be 33 ft. lbs. (45 Nm), plus an additional 90 degrees (1/4-turn). A torque angle meter is recommended.
6. Install the remaining components in the reverse order of the removal process.

3.4L Engine To Remove:

1. Remove the lower intake manifold.
2. Remove the exhaust crossover pipe.
3. If removing the right cylinder head, remove the catalytic converter from exhaust manifold.
4. If removing the left cylinder head, remove the engine oil dipstick and tube.
5. Remove the rocker arms and pushrods.
6. Remove and discard the cylinder head bolts.
7. Remove the cylinder head.
8. Clean the mating surfaces on the following items:
   • Cylinder head
   • Cylinder block
   • Intake manifold
9. Clean the cylinder block bolt threads.

NOTE: During disassembly, keep the valve train components together for proper location during assembly.
To Install:
NOTE: Coat the cylinder head bolt threads using thread sealer.

1. If removed, install the following components:
   • Exhaust manifold
   • Accessory studs
   • Spark plugs
2. Place the cylinder head gasket in position over the dowel pins. Ensure that the THIS SIDE UP note is showing.
3. Install the cylinder head. Cylinder head torque sequence ’99-‘00
   
   Cylinder head torque sequence ’01-05
   
   
4. Install the new cylinder head bolts.
   • Tighten the cylinder head bolts a first pass to 44 ft lb (60 Nm).
5. Tighten the cylinder head bolts in sequence an additional 95 degrees.
6. Install the intake gasket.
7. Install the pushrods and rocker arms.
8. Raise and support the vehicle.
9. Install the catalytic converter and dipstick tube and indicator if removed.
10. Lower the vehicle.
11. Install the exhaust crossover pipe.
12. Install the intake manifolds.
13. Connect negative battery cable.
14. Fill the cooling system.

where is the watter coming out from? did you follow torque sequence / did you have head resurfaced? check block / did you find any thing wrong with the old head gasket? please give more info, so we can give you better assistance , Thank you for using Fixya.

1. On models equipped with airbag, disable airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING .
2. On all models, disconnect battery ground cable, drain cooling system and remove air cleaner.
3. Disconnect accelerator, transmission and cruise control linkages, as equipped.
4. Disconnect fuel line from carburetor or TBI unit and remove fuel line clips as needed, then remove carburetor or throttle body from intake manifold.
5. Disconnect necessary vacuum hoses and electrical connectors, noting position for installation.
6. Disconnect upper radiator and heater hoses from manifold.
7. On Cadillac Brougham models, remove thermostat and housing.
8. On all models, remove distributor.
9. Remove ignition coil, AIR pump, cruise control servo and brackets, as needed.
10. Remove alternator upper mounting bracket and EGR solenoids.
11. Remove manifold retaining bolts and the manifold.
12. Reverse procedure to install, noting the following:

1. Ensure surfaces are clean and dry, then apply 3/16 bead of RTV sealer on each block ridge and apply suitable sealer around water outlets, install gaskets and secure gasket position by extending bead of sealer approximately 1/2 inch onto gasket ends.
2. Install manifold and retaining bolts, ensuring areas between case ridges and manifold are completely sealed.
3. Torque manifold bolts to specifications in sequence shown in Figs. 2 and 3.
4. After installing carburetor or TBI unit, check to ensure no fuel leakage is present.

1. Rearm airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING

On 5.7L engines, install the bolts and torque in sequence as follows:

1. Step 1: 71 inch lbs. (8 Nm).
2. Step 2: 106 inch lbs. (12 Nm).
3. Step 3: 11 ft. lbs. (15 Nm).

Intake bolt torque is 11-14 foot pounds. Note:
to torque bolts & nuts, start in center using
crisscross pattern working outward. And as Far as the sealant goes, you shouldn't need any additional sealant since the new gasket has sealant.(just make sure both surfaces are clean an free of oil.) sometimes if the head or the block show signs of pitting on the matteing surfaces then you could use a litttle of that cooper spray gasket to coat the new gasket.