Powergasket + DIY

[JettaManDan]

Lots of peeps are doing the powergasket..so i thought i'd post a DIY...didn't take any pics..but if you look at the car it's pretty straightforward...this mod does work..intake mani on my car stays cool after driving it hard....

Here is my quick DIY for you....

tools needed:
5mm long T- handle allen head key
7mm allen key
short 5mm allen head key
10mm deep socket and ratchet and extension
flat head screwdriver
extendable magnet
string
clamp to replace the one on the intake mani on the right side

Disconnect battery
Open gas cap to release pressure
Take engine cover off
take the front engine cover off
disconnect your fuel pressure regulator
take off your intake hose from your throttle body
cut the one time use clamp from the tube that goes into the right side of the intake manifold, the one that branches..you only need to take that one off...have a clamp to replace it.
under the front engine cover there are 3 allen head bolts..two 5mm and one 7mm holding the front bracket to the manifold - remove
loosen the metal tray that holds the oil dipstick, lift it up and unclip the dipstick bracket
Under the throttle body is a small rubber hose that may need to be disconnected...can be squeezed and pulled out.
The fuel rail has a black strip holding the wires to the rail..look at it and unclip it from the rail..this give you acccess to the two 5mm fuel rail allen bolts...
using the magnet at the same time you use the 5mm allen to take those 2 bolts out...if you don't use a magnet you WILL drop them
Once the rail is loose...unclip the fuel injectors, and then pull the whole rail up pulling the injectors out of their seats...take some string and tie the rail up at a 45 degree angle to the hood clip..it needs to be out of the way.
now take your 10mm deep socket and remove the 2 10mm nuts on the bottom front corners of the manifold where it mounts to the head..again, use the magnet at the same time so you don't drop them.
Use the long T-Handle 5mm allen ket to then remove the rest of the manifold bolts..again..USE THE MAGNET!!!

Once all those are out..the manifold should come away from the head..just pull it off the 2 front studs..slide the old gasket out..and then put the new power gasket back on. Have a friend hold the manifold away while you do this.
then re-install the reverse of removal...i'd use the magnet to put the bolts back and and try to start them...so you don't drop them.

When putting the injectors back in push them till there is resistance...when you put the 2 bolts back in and tighten them back down it will seat the injectors fine.

Make sure you re-connect everything and put all the bolts back...the manifold bolts can just be hand tightened, i used about 80% of my strength so as not to strip them...

not having any idea what i was doing me and a freind got this done in about an hour and 15 minutes.

Dan

Modified by JettaManDan at 1:32 PM 5-2-2007


Modified by JettaManDan at 9:21 AM 7-30-2007

[Archie Bunker]

Nice Writeup!

[3ur0Tra$h]

you forgot:

Remove gas cap to release pressure in fuel system.

Maybe I am old school but I have always done that when working on anything involving the fuel system.

[SAVwKO]

Quote, originally posted by 3ur0Tra$h »

you forgot: Remove gas cap to release pressure in fuel system. Maybe I am old school but I have always done that when working on anything involving the fuel system.

fuel in yo face ftl

[3ur0Tra$h]

Quote, originally posted by SAVwKO »

fuel in yo face ftl

try brake clean or gum cutter in "yo eye" that SUCKS. Eye teared for almost 2 days, my girlfriend loved it "It is nice to know my man is sensative" LOL

[cirial]

Did you install the newer Powergasket that seals itself or something like that? I remember them coming out with a newer revision of it.

[JettaManDan]

never took off the gas cap..had no issues..still a good tip...

the powergasket plus is the newer one and does not require a sealant...it is a fiberous material that crushes a little bit i think and seals well...have had no issues....

Dan

[skibum525]

weren't there some issues a while back and the dangers of the power gasket to the engine??? I don't remember for sure, but I thought I read that somewhere

[bluebora20v]

Quote, originally posted by skibum525 »

weren't there some issues a while back and the dangers of the power gasket to the engine??? I don't remember for sure, but I thought I read that somewhere

Older spacer gaskets were melting. I don't know if it was the Powergasket or another brand though. I believe it has been taken care of in newer versions.

JMD, what are your thoughts about the product since you installed it?

[JettaManDan]

the older power gasket melted on some cars on BT ones specificially...and then casued issues...

so far i am very happy...have tested it several times..hard boost run and then popping the hood..and the mani is cool...can't give any better endorsement..seems a tad longer before heat soak sets in....not really much else to say...combine this with a front mount and you will have the coolest intake charge you can get..and "preserve" all the power you can make...

[_leo_]

what abotu pics, i like pics

[JettaManDan]

Quote, originally posted by _leo_ »

what abotu pics, i like pics

don't have any...sorry......

[JettaManDan]

bump for others....

[vdubbun]

Added to the DIY!

[JWoody]

I know its a little late but I installed my PowerGasket today and forgot the damn camera , so here is the OE gasket, and you can clearly see how thin and wimsy it is...NewSouth did a great job with the Plus in comparison...

-J

[JettaManDan]

bump for people who were asking....

[sciroccojoe]

i put one of these on my apr stage 3+ AE, no problems yet! its been on for about a month now! so far so good!

[shred_65]

what's the difference with the "power gasket" & "power gasket plus"?

[Blue20thAE]

Quote, originally posted by 3ur0Tra$h »

you forgot: Remove gas cap to release pressure in fuel system. Maybe I am old school but I have always done that when working on anything involving the fuel system.

hahaha yea for sure...and disconnect batt. - if you open a door the injectors spurt some fuel all over

[JettaManDan]

Quote, originally posted by Blue20thAE »

hahaha yea for sure...and disconnect batt. - if you open a door the injectors spurt some fuel all over

yep...added.....i just kept the door shut

[JettaManDan]

Quote, originally posted by shred_65 »

what's the difference with the "power gasket" & "power gasket plus"?

powergasket plus is a different material from the orginal...can take higher temps and does not require sealant...

[frprado]

Quote, originally posted by 3ur0Tra$h »

try brake clean or gum cutter in "yo eye" that SUCKS. Eye teared for almost 2 days, my girlfriend loved it "It is nice to know my man is sensative" LOL

Yeah sensitive to brake cleaner. Spary some in her eye and call here an "overly sensitive wowan" for the next to days...

[dalekurt]

I recently did this, but the support bolt for the front of the intake manifold will not go in because the powergasket is thicker than the OE gasket, so the intake is a raised and no longer in line with the holes, how do you fix this issue?

[blackgti1340]

nice write up!

[dalekurt]

Just spoke to a support person on NewSouth Performance who confirmed what my mech said, which was the widen the hole for the support bolt.

[SteveC]

The fix is to enlarge the hole in the bracket just enough so that the bolt will slide in and then everything should line up properly.

[JettaManDan]

i never had a problem with the support bolt...wierd...

[Boosted96GSX]

This was a mod I was looking at doing, but isn't this gasket working against you. Yeah the intake mani stays a little cooler, but at what price. If no or little heat is transfering into the intake mani, then it all is being held in the head. The intake mani serves as an outlet for all of that heat, and now it is being trapped in?

Just my .02

[allmotor6]

Quote, originally posted by Boosted96GSX »

This was a mod I was looking at doing, but isn't this gasket working against you. Yeah the intake mani stays a little cooler, but at what price. If no or little heat is transfering into the intake mani, then it all is being held in the head. The intake mani serves as an outlet for all of that heat, and now it is being trapped in? Just my .02

ohh, are we on to something here?

[SteveC]

Quote, originally posted by Boosted96GSX »

This was a mod I was looking at doing, but isn't this gasket working against you. Yeah the intake mani stays a little cooler, but at what price. If no or little heat is transfering into the intake mani, then it all is being held in the head. The intake mani serves as an outlet for all of that heat, and now it is being trapped in? Just my .02

We were concerned about that also as we developed the PowerGasket.

1. The head does is not designed to be cooled by the intake manifold
2. The head is designed to be cooled with antifreeze in your radiator system. With coolant flow of 10-20 GPM, the head does not need the intake manifold for cooling.

Our testing also showed that the head temperature did not change when a PowerGasket was installed.

[JettaManDan]

there is absolutely no way the intake mani is designed as a heat sink for the head....if it was, it would have cooling vanes all over it...so how do you explain the MK5 2 liter turbo's with plastic intake manifolds? or VR'S with plastic intake manifolds? so they aren't being cooled then? sorry...but that was the most ridiculous thought i have heard on vortex in a while....the truth is that the cooled air going into the head does more for the heat issues than the heat being transferred out...if the intake mani is hot, and the head is hot..guess what? the intake charge is hot and cools nothing....but with a cool intake mani the air going into the cylinder head is cooler and keeps that cooler in turn....do me favor and take your intercooler out of your car and run a straight metal pipe to your intake mani, becasue hell, the pipes are connected and it must not be drawing enough heat from the head with it in there...right? i don't rant often..but geez that was dumb as hell....

thanks steve for your informed explanation of how a head is trully cooled


Modified by JettaManDan at 7:48 PM 4-2-2008

[1.8Tjettta01]

correct me if i'm wrong,

steve said "" Our testing also showed that the head temperature did not change when a PowerGasket was installed.""

SO that means the powergasket is a Gimmick?

Yes or no?

[SuckerPunch]

Quote, originally posted by 1.8Tjettta01 »

correct me if i'm wrong, steve said "" Our testing also showed that the head temperature did not change when a PowerGasket was installed."" SO that means the powergasket is a Gimmick? Yes or no?

its not supposed to keep the head cooler, its supposed to keep the intake mainfold cooler

[1.8Tjettta01]

Alright thanks, i just read it backwards. no worries. thank you.

[Boosted96GSX]

Wow hope you feel better