General intake manifold removal tasks and tips



#1
There are 4 12mm head bolts holding a metal bracket to the engine and the intake. The bracket does not need to be removed, just remove the bolts. The fourth one, top passenger side can actually stay. There is one 10mm bolt holding your IAC valve wire. These bolts are seen and removed from below. You can remove 2 of the intake nuts from below as well (12MM). Up top you have to remove the throttle body, the vacuum lines and the steel pipe assembly (2 10mm bolts) remove the fuel line on the fuel rail, Unplug your injector resistors and the other two connections (driver's side firewall, 3 plugs), then remove the entire fuel rail and injectors with the harness. (difficult). Disconnect the fuel return line. Remove the EGR valve. disconnect the cooling lines beneath the throttle body, that are attached to the intake. Remove the throttle cable and throttle body assembly. Remove the remaining 12mm nuts, there are 10 total, I believe.
Your PCV valve connection will probably get destroyed once you get the intake off. Heat the broken hose on the box at the back of the engine with a torch to get it off, and replace that hose with some 3/8 hose and use an adapter to 1/2 inch hose for your new pvc connection.
Make and take you time, and you will succeed. Using appropriate socket extensions, you can get the nuts off the bottom passenger side
. Tip, when removing and re-installing these hidden intake nuts, put masking tape in your socket to hold the nut while you blindly install the nut. (you will do this with at least the two passenger bottom nuts on the intake)
Take pictures and put nuts and bolts back on where you took things off so you don't mix them up.
When you reattach your cooling hoses, make sure the ends are not punctured. You likely have to pry at the larger one to get it off. You can cut the one larger hose back about 1 inch without having to replace it.
 






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