5 replies to this topic

[Ordex]

I'm currently sourcing parts to replace my air intake tract as it's broken in front of the primary turbo.

I realise this is a big job - there is a guide here. It needs to be done.

 

While I have the intake manifold off I'm planning to replace any coolant and fuel hoses under there and the o-rings on the coolant feed into the block. These are likely 20+ years old so seems time to do it. Is there anything else that can or should be replaced/maintained while the intake is off?

[Jimbo]

Wouldn't be a bad idea to replace the intake manifold gaskets. Could always give the turbos a good clean with some degreaser also.

I would ditch the spring clamps when you replaces all the hoses and replace with worm drive clamps for extra security, too.

[Ordex]

Awesome thanks for that. Yeah any gasket, etc I remove will be replaced and I'll be cleaning everything as much as possible while it's all off.

[Barbbachello]

Good time to inspect the turbos for play and so on. Could give the manifold a lick of paint too if you feel so inclined 

[Ordex]

Ok so over the last three weekends I've managed to get the intake manifold off!

 

The guide I linked to earlier was missing a few things so here are all the steps:

 

1. Disconnect fuel pump and relieve pressure
2. Drain coolant
3. Remove battery
4. Remove washer bottle
5. Remove air intake box
6. Remove BBOD
7. Remove intercooler
8. Disconnect charcoal canister (2 pipes, big on left)
9. Remove coolant header tank
10. Unplug round electrical connector by air intake box
11. Disconnect oil breather pipe from head (driver side)
12. Unplug white single wire electrical connector under IC (knock sensor)
13. Disconnect turbo inlet pipes
14. Disconnect 3 fuel lines (black on top, blue in middle, red on bottom)
15. Disconnect oil breather pipe from head (passenger side)
16. Remove alternator
17. Unplug 2x square electrical connectors near battery and unbolt bracket
18. Disconnect water temps, oil pressure, crank position and power steering pump electrical connectors
19. Disconnect primary turbo coolant return
20. Disconnect brake booster feed from manifold
21. Disconnect spark plugs
22. Disconnect throttle cable
23. Disconnect boost gauge
24. Disconnect coolant lines to/from throttle body
25. Disconnect cam position sensor
26. Pry up PCV (I broke an old brittle pipe doing this)
27. Lift intake manifold free

[Ordex]

It's been 3 months and I finally managed to get everything back together!

 

I'll post the rest of the story over here on my original thread