[DML] Unusual Vacuum Leak

["David Teitelbaum" <jtrealty@xxxxxxxxxxx>]

I am working on another car today and had to remove the intake
manifold. After I removed it I noticed the knock-out plug on the front
right side was deformed to the point that you could see a large leak.
I figured out that at one point someone must have used too long a
screw to fasten the air cleaner on. If you do that in the front-most
position  the screw will touch the knock-out plug and bend it. This is
one you could never see until you remove the intake manifold. It is
also a lesson to always try to use the correct length bolts. Sometimes
things are held together with varying length bolts. You MUST note the
correct positions for each so you do not put a long one in a short
spot and vice versa. In this case even if you put the correct bolt in
after using the wrong bolt the damage will be done. A quick way to
inspect for this leak is to remove the "W" pipe and while having
someone hold a flash light pointing at the knock-out plug look inside
for any sign of light. This will cause the whole right side to run
lean, especially the front cylinder. It will also keep you from
getting the idle right or being able to properly set up the mixture.
Another big problem area is the brass idle motor pipe where it goes
into the mixture unit. If not done carefully the "O" ring seal gets
damaged and leaks. I also see a lot of cars that do not have a plug in
the hole over the mixture screw. I cannot overstress the importance of
finding and fixing ALL of the  vacuum leaks if you want to get the
motor to run right.
David Teitelbaum
vin 10757 




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