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removal of intake manifold
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Old 09 Apr 2012, 07:34 PM   #1 (permalink)
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removal of intake manifold

i havnt found on here a tutorial of taking the intake manifold off...
i thught i would post up how to take it off not to hard rateing out of 5 on diffecalty i would say 3...

Off the top of my head you have to disconnect the below: (I may miss one or 2 things out, but to give you a pretty good idea…)

First off, completely remove:
Strut Brace if needed
TMIC or FMIC IC pipes
Battery
Washer bottle
Pulley cover and throttle cable
Alternator (this is done by loosening the bolt connecting it to the AC pump assembly, and then both the bolts on the bracket to the front left of the alternator. This bracket provides the tension for the PS pump and alternator pulleys. Once loosened, the alternator will drop allowing you to remove the belt, and then free the alternator. Remove electrical connections)

Then disconnect 'Hard' Connections:
HT leads
Carbon canister pipes at the front left bottom corner
Fuel lines rear top right
Header tank (2 bolts holding it to the manifold, coolant pipes on top, and 1 pipe underneath.
coolant pipe to left side, middle of block
coolant pipe to right side, middle of block
Crankcase Breather pipe at back of block going to back of manifold.
Breather pipes attached to inlet pipe
Pipe which goes from the rear right top leg of the manifold, not sure what this does, but goes to the back of the engine bay.
Air box or induction kit pipe attached to inlet pipe
Defi control box for gauges (if you have one)
Relevant boost pipes
8 bolts connecting manifold to the block

Then the 'Electrical' connections:
Crank Sensor on the front top of the block (brown plug under alternator)
White triangular electrical connection in the same location
Another white electrical connection in the same location!
(3 in total behind / under alternator)
Black / Brown plug at the front left of the block, behind the AC assembly.
White electrical connection to the rear of the block behind the manifold
Wiring loom connection to the left of the block, white plug.
Wiring loom connections to the right of the block, grey and brown plugs (IIRC?)
Throttle position sensor
Idle control valve

Once all the hard and electrical connections have been disconnected, carefully lift the manifold out checking that nothing else is still connected.

You may need to release the wiring looms as they may get caught up on other ancillaries as you lift it out.

You will need to lift up and then to the left to clear the AC pipes on the right. You will need to make sure your clearing the header tank mount (under the header tank) as this sticks up and snags the manifold as you try to lift it out over it.
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Last edited by Lamby2k12; 09 Apr 2012 at 09:35 PM.
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Old 10 Apr 2012, 09:47 PM   #2 (permalink)
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Re: removal of intake manifold

good thread, there is alot to clear on these things!
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Old 10 Apr 2012, 11:12 PM   #3 (permalink)
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Re: removal of intake manifold

Only problem I had was remembering where to put the bolts at the bottom. It's horrible when u bolt the manifold down connect the fuel lines then remember shit forgot that bolt in my pocket. I just take photos on my phone before I remove the bolts. Sad I know but it works
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Old 10 Apr 2012, 11:29 PM   #4 (permalink)
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Re: removal of intake manifold

I've taken to using tyre pen to mark my bolts and pipes, even invested in a label printer pretty handy when doing electrics!
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Old 11 Apr 2012, 07:46 AM   #5 (permalink)
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Re: removal of intake manifold

Quote:
Originally Posted by Harryfor View Post
I've taken to using tyre pen to mark my bolts and pipes, even invested in a label printer pretty handy when doing electrics!
Yer they are some of the plugs a coloured too or they have diffrent groves
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