Name ________________________________________________________ Date _________________

Instructor _____________________________________________________ Period ________________
37 Copyright by Goodheart-Willcox Co., Inc.
After completing this job, you will be able to remove and install a gasket on an automotive part.
As you read the job instructions, answer the questions and perform the tasks. Print your answers
neatly and use complete sentences. Consult the proper service literature and ask your instructor for help as
Before performing this job, review all pertinent safety information in the text and
discuss safety procedures with your instructor.
1. Obtain a vehicle to be used in this job. Your instructor may direct you to perform this job on a
shop vehicle or engine.
2. Gather the tools needed to perform the following job. Refer to the tools and materials list at the
beginning of the project.
Remove a Gasket
1. Make sure all lubricant has been drained from the unit containing the part and gasket to be
Skip the preceding step if the lubricant does not cover the part to be removed when the
vehicle is not running. Care should be taken that the lubricant is not contaminated with
gasket material or other foreign material during this task.
2. Remove the part covering the gasket. You may need to lightly pry the parts apart. Be very careful
not to damage the sealing surfaces.
3. Scrape all old gasket material from both sealing surfaces.
4. Thoroughly clean the removed part and remove any gasket material or other debris on the related
components in the vehicle.
5. Inspect for gouges, cracks, dents, and warped areas on the sealing surfaces of the removed part
and assembly to which it attaches.
Describe the condition of the sealing surfaces of the removed part and the corresponding surfaces
on the vehicle: __________________________________________________________________
6. Repair or replace the parts if defects are found.
Project 2: Job 5—Remove and Install a Gasket
38 Copyright by Goodheart-Willcox Co., Inc.
Install a Gasket
1. Obtain a replacement gasket and compare it with the part’s sealing surface. See Figure 5-1.
Make sure that the following conditions are met:
• The replacement gasket is the correct size and shape. ___
• The gasket material is correct for this application. ___
2. Place a light coat of sealer or adhesive, as applicable, on the removed part to hold the gasket in
place during reinstallation.
Sealer may not be needed on all applications. Check the service manual for specific
3. Place the gasket in place on the part.
4. Reinstall the part, being careful not to damage or misalign the gasket.
5. Install the fasteners. Do not tighten any fastener until all fasteners are started.
6. Tighten all fasteners to the correct torque. Follow these rules to avoid gasket damage and leaks:
• Tighten the fasteners in the manufacturer’s sequence. If a sequence is not available, follow the
procedures shown in Figure 5-2. If the part is irregularly shaped, start from the innermost
fasteners and work outward.
• Tighten each fastener slightly, then move to the next fastener. Repeat the sequence until final
torque is reached.
• Be especially careful not to overtighten fasteners holding sheet metal components.
• Rubber gaskets, sometimes called “spaghetti gaskets,” require very low torque values. Figure 5-3
shows a typical spaghetti gasket. Be extremely careful not to overtighten these types of gaskets.
Figure 5-1. Compare the new gasket to the part-sealing surface to ensure that it is correct.
Project 2: Job 5—Remove and Install a Gasket (continued)
Name ________________________________________________________
39 Copyright by Goodheart-Willcox Co., Inc.
Project 2: Job 5 (continued)
Figure 5-2. A—When tightening a square or rectangular pan or cover, always start from the center and work
outward. This allows the gasket to spread out, improving the seal. B—When installing the fasteners on a
round cover, tighten in a star or crisscross pattern.
16 18 14
15 17 19
Figure 5-3. A spaghetti gasket used on an intake manifold is shown here. Some spaghetti gaskets are simply
sections of flexible rubber that strongly resemble spaghetti. They are extremely easy to overtighten.
40 Copyright by Goodheart-Willcox Co., Inc.
7. Add the correct type and amount of fresh lubricant into the unit as needed.
If there is any possibility that the lubricant was contaminated during the gasket
replacement process, it should be replaced.
8. Operate the vehicle and check for leaks.
Job Wrap-Up
1. Clean the work area and return any equipment to storage.
2. Did you encounter any problems during this procedure? Yes ___ No ___
If Yes, describe the problems: ______________________________________________________
What did you do to correct the problems? ____________________________________________
3. Have your instructor check your work and sign this job sheet.
Performance Evaluation—Instructor Use Only
Did the student complete the job in the time allotted? Yes ___ No ___
If No, which steps were not completed? ____________________
How would you rate this student’s overall performance on this job? ________________________
1–Excellent, 2–Good, 3–Satisfactory, 4–Unsatisfactory, 5–Poor
Comments: __________________________________________________________________
INSTRUCTOR’S SIGNATURE _________________________________________________
Project 2: Job 5—Remove and Install a Gasket (continued)

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