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DIY - Intake Manifold Removal

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Old 02-27-2008 | 12:34 PM
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RajDatta's Avatar
RajDatta
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From: NJ
Default DIY - Intake Manifold Removal

Tools Required:
Hex Head Sockets: 4mm, 6mm
Ratchet
Phillips, flat screwdrivers
Wire Clippers
Torque Wrench
Open End Wrenches: 13mm, 17mm, 19mm

Remove "PORSCHE" vanity cover by taking four hex head bolts offDisconnect Fuel Rail using 17mm and 19mm open end wrench
Disconnect cruise control cable from the locknut and remove it from the unit using 13mm open end wrench
Disconnect injector harness from fuel rail by pressing on clips. Make sure you catch the rectangular seals for injector connectors
Remove hex head bolts on the intake runners using 6mm hex head socket
Remove four 10mm bolts holding injector rail. Pull it off carefully
Remove vacuum line to Fuel Pressure Regulator and put rail aside
Loosen clamps holding the coolant hose in the back of head and air breather hose between cylinder 3 and 4
Remove 13mm locknut holding throttle cable and move it out of the way
Remove two 10mm bolts holding O2 sensor clip
Pry brake booster hose off brake booster
Loosen clamp holding checkvalve line to nipple under intake manifold, pull line off
Remove 13mm bolt holding intake manifold to drivers side engine mount
Remove 10mm bolt holding oil dipstick, pull dipstick off
Clip tiewraps that hold engine harness to MAF and throttle position sensor to throttle body
Unclip engine harness that connects to Throttle Position Sensor, MAF and Idle Stabilizer valve
Remove front coolant neck using 6mm hex head socket
Disconnect clamp holding hose for coolant tank
Lift and pull Intake manifold
Be prepared to catch some coolant when you disconnect coolant neck. You can avoid did by draining coolant prior to process

I will add pictures and installation torques shortly. There might be a revision or two. This is all based on memory.
Raj

Last edited by RajDatta; 02-27-2008 at 07:52 PM.




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