As above, im planning on haivng the intake manifold off to replace the orings in the AOS, is there any other jobs anyone can recommend while im in there? Replacing hoses etc? Any advice on this would be great!

 

I'd suggest that you at least be prepared to replace hoses, or at least connectors, as I broke several during my disassembly.

Anyway, I'd suggest getting a wire brush and scrubbing the manifold and even the cam carrier with it. Getting rid of that goldish oxidation goes a long way towards making the engine look nicer.

BB.

 

Clean the intake ports. The will more than likely have 20+ years of crude in them.

 

Clean out the ISV, check your bellhousing ground, ref/speed sensor, powdercoat the intake, new plugs, don't get crap in the head... replace the heater valve...

 

Injectors cleaned and rebuilt. New gaskets. Clean everything you can see.

 

AOS seals. Hey, you're in there...

 

I'm about to do this too. Anyone know a good source for the hose that connects from the ISV to the J boot? This is the only part I don't have.

 

pelicanparts.com i am going in there my self to fix the hose for the ISV and i will be replacing the intake gaskets and and also cleaning, adjusting, the ISV and removing as much crud as possilbe

 

Check your turbo for leaks!

 

sorry, mines a S2, no turbo in there :P

 

If it's a pre-S, do a Venturi delete with a vacuum hose update kit. If not, check the vacuum connections to the cycling valve if you're not bypassing it, and also to the ISV.

 

Replacing every vacuum line and connector piece you can see wouldn't be a bad idea. Clean grounds at the back of the engine (one might be the bellhousing ground - they are about 2" apart). Engine temp sensor is under there too (NTC II), so check that. Throttle's pretty accessible on the S2, right?, so no need to rebuild that right now (not so for the S).