- For the end pieces, this really varies. More detailed bit down below.
- For the valley pan, I have personally always used copper coat. Use a bead of RTV around the water jackets.
- I have always put the oil baffle onto the new intake (its not a heat shield really).
- I have been able to use a strap wrench before. But another time I just had to cut it flush, meaning it was shorter on the new intake.
- This varies greatly depending on the year and model of your FSJ
For the intake end pieces, there are mostly two schools of thought. Those that use RTV for the whole thing, and those that use the rubber pieces.
Personally, I have always used the rubber pieces, and never had one leak. BUT... prep is super important. Before they are put on, ALL oil has to be removed from the metal surfaces it touches. This includes oils from your fingers. Use enamel reducer or similar to wipe down the surfaces with a lint free cloth. ALSO wipe down the rubber pieces themselves, they will have residual residue from manufacturing on them. Once they are in place, then some black RTV (RTV intended for oil) can be used in the corners next to the heads. If done properly, the rubber pieces will actually kind of bond to the metal, and will never leak.
The other school of thought is to use RTV for the whole thing. Prep is also important here. And its important to not add too much, and also important to have enough to fill the gap.
As a side note, installing the intake is kind of a pain. I have found it much easier to have a second person handy to push down evenly on the intake while starting the bolts. With the valley pan the intake won't just sit down, it will want to pop up.