removing the lower intake manifold
08-10-02, 08:24 PM
#1
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removing the lower intake manifold
hey I'm trying to install my pineapple racing sleeves I just got.
I managed to remove the top intake manifold, but now the lower one looks much harder to remove.
There's a bunch of hoses on the right side, and I can't remove them. Should I just cut them and replace them?
Also do I have to remove the alternator to do this?
Any tips would be cool
thanks
I managed to remove the top intake manifold, but now the lower one looks much harder to remove.
There's a bunch of hoses on the right side, and I can't remove them. Should I just cut them and replace them?
Also do I have to remove the alternator to do this?
Any tips would be cool
thanks
08-10-02, 08:29 PM
#2
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Ive done this a couple times on my S4. I dont think you'd need to remove the alternator to get it off. Try using needle nose pliers and moving them back and forth before you cut them. Also be careful when you're putting everything back together as far as overtightening. But if you're vacuum lines are rock hard you might wanna replace them. ML5150 just had his manifold off a couple weeks ago, he might be able to help you out.
08-10-02, 09:05 PM
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I've done this so many times it isn't funny 
the stuck on vac hoses just need a little twist. Get a plyers and turn em a bit until they break free (warning: you may break a hose or 2, cost: $0.39) There are 2 nasty bolts underneath the manifold just above the headers/exhaust manifold. They ARENT listed in the Haynes (it only shows 4 of 6). The whole spider doesnt need to come off, just disconnect the hoses. the 6-ports come right off WITH the manifold.
post up any more specific ?'s you may have.
the stuck on vac hoses just need a little twist. Get a plyers and turn em a bit until they break free (warning: you may break a hose or 2, cost: $0.39) There are 2 nasty bolts underneath the manifold just above the headers/exhaust manifold. They ARENT listed in the Haynes (it only shows 4 of 6). The whole spider doesnt need to come off, just disconnect the hoses. the 6-ports come right off WITH the manifold.
post up any more specific ?'s you may have
.
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08-11-02, 01:23 AM
#9
Rotary Freak
Also, dont even THINK of re-using those vaccum lines!!!
Leave them all attached at one end or another.
then, during re assembly, cut a new length from a 20 foot replacements rubber vac / washer hose.
Each one MUST BE REPLACED!
DO NOT reuse any hoses that you have to remove.
Each one will have a small vaccum leak and collectivly you will have a massive vac leak when your all finished.
Also make sure you clean the manifolds/air bleed and block areas with lots of carb cleaner and a bottle brush.
dont scrub the plactic air bleeds located in the secondary manifold. (plenum)
Use a can of gasket remover and spray them, they have tiny holes in them that are now clogged with carbon.
the gasket remover will sit on the plastic and eat the carbon without you having to touch the bleeds, then spray them with carb cleaner to rinse.
Also rotate the actuator rods and make sure they move VERY loosely.
You might have to remove them and clean them.
once you do this they will move very loosely if you work them a bit.
TO get the screw off next to the bolt for the actuator rods, you will have to:
a) hack a grove across the screw to make a flatblade slot and use a stout flatblade to remove them
b) use a impact driver and hammer to remove the phillips screw.
(I use the "A" method and replace them with bolts of the same thread and star washers)
When you re assemble the intakes, you can avoid vaccum leaks at the seams by buying a bottle of "Super 300" paintable sealant.
Use it to coat the mating surfaces. and then bolt them back on.
I have done this work too many times to count, so any questions you can PM me.
I do this for stock sleeves though.
Pinapple sleeves are no different procedurally.
Now is your chance to also send your injectors to NAPA to be cleaned and rebuilt.
make sure if you do this, to send them with all the rubber on them, they will replace it with new rubber.
Dont let them forget this, its part of the job your paying for.
Leave them all attached at one end or another.
then, during re assembly, cut a new length from a 20 foot replacements rubber vac / washer hose.
Each one MUST BE REPLACED!
DO NOT reuse any hoses that you have to remove.
Each one will have a small vaccum leak and collectivly you will have a massive vac leak when your all finished.
Also make sure you clean the manifolds/air bleed and block areas with lots of carb cleaner and a bottle brush.
dont scrub the plactic air bleeds located in the secondary manifold. (plenum)
Use a can of gasket remover and spray them, they have tiny holes in them that are now clogged with carbon.
the gasket remover will sit on the plastic and eat the carbon without you having to touch the bleeds, then spray them with carb cleaner to rinse.
Also rotate the actuator rods and make sure they move VERY loosely.
You might have to remove them and clean them.
once you do this they will move very loosely if you work them a bit.
TO get the screw off next to the bolt for the actuator rods, you will have to:
a) hack a grove across the screw to make a flatblade slot and use a stout flatblade to remove them
b) use a impact driver and hammer to remove the phillips screw.
(I use the "A" method and replace them with bolts of the same thread and star washers)
When you re assemble the intakes, you can avoid vaccum leaks at the seams by buying a bottle of "Super 300" paintable sealant.
Use it to coat the mating surfaces. and then bolt them back on.
I have done this work too many times to count, so any questions you can PM me.
I do this for stock sleeves though.
Pinapple sleeves are no different procedurally.
Now is your chance to also send your injectors to NAPA to be cleaned and rebuilt.
make sure if you do this, to send them with all the rubber on them, they will replace it with new rubber.
Dont let them forget this, its part of the job your paying for.
08-11-02, 10:05 AM
#10
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at $24 per injector I can't afford it 
Since I have to replace all the vaccum hoses I remove, can I just cut them? Like the one attaching to the fuel injectors etc...
There's no special shaped one I have to get at the dealer correct?
thanks
Since I have to replace all the vaccum hoses I remove, can I just cut them? Like the one attaching to the fuel injectors etc...
There's no special shaped one I have to get at the dealer correct?
thanks
08-11-02, 11:46 AM
#11
Rotary Freak
Cutting them is MORE work.
Just twist them loos with needle nose pliers and leave them connected at one end.
Trust me on this.
If you cut them and two ends seem to match with two ends of another two ends, then how will you tell what goes where?
There are no hoses attaching to the fuel injectors.
You must mean the oil injectors.
Just remove them at one end.
ALSO...
while you are removing the oil injectors on the manifold, use a 3/8 inch box end wrench to loosen them.
you MUST MUST MUST also hol the metal collar clamp of the oil injector tube with needle nose pliers while you do this otherwise you will break the tube and those are $20 each!
Just twist them loos with needle nose pliers and leave them connected at one end.
Trust me on this.
If you cut them and two ends seem to match with two ends of another two ends, then how will you tell what goes where?
There are no hoses attaching to the fuel injectors.
You must mean the oil injectors.
Just remove them at one end.
ALSO...
while you are removing the oil injectors on the manifold, use a 3/8 inch box end wrench to loosen them.
you MUST MUST MUST also hol the metal collar clamp of the oil injector tube with needle nose pliers while you do this otherwise you will break the tube and those are $20 each!
08-11-02, 12:59 PM
#12
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well, after playing around with it for 2 hours, I still can't remove it. 
How many bolts are there? I removed 3 vertical ones on the right side, and 2 horizontal on the left side. The thing won't budge.
Do I have to remove the thingy on the center of the manifold?
I might call a mechanic tomorrow to do it. A little too hard for me.
thanks!!!!!!!!!!!
How many bolts are there? I removed 3 vertical ones on the right side, and 2 horizontal on the left side. The thing won't budge.
Do I have to remove the thingy on the center of the manifold?
I might call a mechanic tomorrow to do it. A little too hard for me.
thanks!!!!!!!!!!!
08-11-02, 04:59 PM
#15
Rotary Freak
four in in each corner, and two underneath.
Run your fingers along the bottom to find them.
they are nuts instead of bolts.
remove the AVC off the manifold and the 5th and 6th port actuators.
why are you tortureing yourself?!
just reat the Factory service manual for any 2nd gen car and it will show you the steps.
Run your fingers along the bottom to find them.
they are nuts instead of bolts.
remove the AVC off the manifold and the 5th and 6th port actuators.
why are you tortureing yourself?!
just reat the Factory service manual for any 2nd gen car and it will show you the steps.
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