Intake Manifold
Removing the intake manifold is something that must be done as a precursor to many other repairs. For example many of the vacuum lines run UNDER the manifold, so removal of the intake manifold is necessary.
Before you remove the intake manifold, you will have to remove the fuel rail.
Here you can see the intake manifold with the fuel rail removed. First remove the spark plug boots by tanking on them from the elbow. It may help to take some electrical tape, wrap the ends of the wires, and label the cylinder numbers. This will help things get back together much faster in the end. Remove the pipe from the inter cooler outlet to the throttle body by removing the two hose clamps. Remove the oil dip stick tube support bracket from the manifold. If you have cruise control, there is a cable running across the intake manifold to the cruise control servo motor (mounted on the passenger firewall). Remove the support bracket by removing the single bolt that attaches the support bracket to the manifold. Disconnect the cable attached to the cruise control motor by gently pulling the cable off the ball post. Remove the vacuum accessory line from the manifold. Note how the washers are installed. Remove the two hoses that attach on the passenger side of the intake manifold. Factory hoses are attached with a crimp style clamp, some people have replaced those with traditional style hose clamps. My previous owner reattached them with zip ties. My hoses were so bad they broke like 1930s bakelite when I tried to remove them. Now it is time to remove the throttle cable from the throttle body. Rotate the throttle towards the front of the car so you can see the system better. Then, pull up some slack in the cable, and slide the cable out of the hole by rotating the cable stop. Remove the intake manifold support bolt. The bolt is towards the front of the manifold near the throttle position sensor. The hole is actually slotted, so you can loosen the bolt if you would like instead of just removing it. I assume that this is just a slotted hole to help with lining up the manifold during re-installation? Remove the two bolts near the oil/air separator bracket. Find them just by the oil cap. Under the throttle body, there is a vacuum line running to the throttle body. Unplug this line. I didn't know about it until AFTER I started removing the manifold. Just feel around under there, and there is a 90* nipple with a hose attached to it. Yank it off. Remove the hose clamp that attaches to the throttle body, and loosen up the connection between the hose and throttle body if it has formed a seal. Remove the actual intake manifold bolts using 6mm Allen head socket. BE VERY CAREFUL. They are attached to the head. You don't want to strip them. Remove the intake manifold by lifting straight up from the head, and then lifting up towards the rear of the manifold. Then pull it forward to pull the front of the intake manifold out of the hose that connects to the throttle body. Cover the intake ports somehow. Use red rags, blue shop towels, duct tape, etc. You want to keep junk from falling into the intake ports like tools, dirt, fluids, etc.
