Intake manifold installation

[br289165]

I wanna change intake manifolds on my P5 to the PG manifold. Can anyone tell me the difficulty of this job? Whats the hardest part?

 

[blueprotegelx]

It depends on how mechanicly inclined you are. The first time I did it, it was hard b/c I couldn't get to the bolts on the lower flange of the manifold. But once I found them and got familiar the install and unistall became easier. My hardest part was probably between those lower bolts, and the process of removing off of the head and out. Takes a little bit of manuevering. Honestly though I did not even think it was hard at all, those two were just somewhat more difficult than rest. Make sure you get all new gaskets and sealant and seal it tight!

 

[JCell]

the hardest part for me is removing the brace from under the car

the top is cake

 

[br289165]

You had to remove the crossmember?

the hardest part for me is removing the brace from under the car

the top is cake

 

[bgibb68]

no there is a brace that goes from the block to the bottom side of the intake....it's easy.....the hardest part i think is labeling all the plugs and wires to make sure you get everything back......but i can now take the intake off and have back on in an hour

 

[br289165]

Any tips on the throttle cable removal /adjustment or anything else connected that needs unbolting?

no there is a brace that goes from the block to the bottom side of the intake....it's easy.....the hardest part i think is labeling all the plugs and wires to make sure you get everything back......but i can now take the intake off and have back on in an hour

 

[JCell]

You had to remove the crossmember?

no, there is a brace that holds the intake manifold, 2 bolts on the IM, 2 on the block

 

[blueprotegelx]

yeah...i am pretty good about memorizing where things go so I honestly did not think that was even hard. I really didn't find the intake manifold that hard to do. but like i said it depends on your mechanical level! I had mine off about 5-6 times in one day b/c i had a vacuum leak somewhere, finally i got some gasket maker and put it on both sides of all my gaskets and my nsn thermal spacer and that did it. i think there was a leak where the spacer was though. but it's fixed and i love the feeling of it now.

 

[br289165]

I'll take digital pics and maybe videotape before i start just in case I forget,my memory sucks!
thanks for the help

yeah...i am pretty good about memorizing where things go so I honestly did not think that was even hard. I really didn't find the intake manifold that hard to do. but like i said it depends on your mechanical level! I had mine off about 5-6 times in one day b/c i had a vacuum leak somewhere, finally i got some gasket maker and put it on both sides of all my gaskets and my nsn thermal spacer and that did it. i think there was a leak where the spacer was though. but it's fixed and i love the feeling of it now.

 

[blueprotegelx]

if you do forget just post a pic. we'll tell ya. lol

 

[JCell]

its really not hard to figure out the vacuum line route. they are all twisted, angled, and sized so if it doesn't look right, its not

 

[bgibb68]

its really not hard to figure out the vacuum line route. they are all twisted, angled, and sized so if it doesn't look right, its not

well if you do go the pg mani route, you need a vac distribution block cause there are a couple less vac ports on that mani than the stocker

 

[brentmc79]

The hardest part for me was that damned metal tube that goes from the exhaust manifold to the intake manifold. All of the nuts/bolts that actually hold the intake manifold to the block are easy to get to once you find the right angle, and the two 12mm bolts on the underside brace weren't a problem.

 

[Breeegz]

I just wanna pull the top off, do i need to take the whole thing out (including throttle assembly) to get the top off?

I have everything off up top, and the top half is too tight to come off by itself (those studs on the IM and the studs on the block are at about 90 degrees from each other) Can I just loosen the two below and pop it off?

ok.. hopefully I can get a decently quick response, I'm back out to figure out how to jack it up with my jacks and without my "drive up on 2x4s" technique.. Damn my car is low.

Be back soon

 

[aMaff]

I've never personally pulled one, but from what I've read, I'm very certain that the top half can come off w/ it still on the car.

 

[Breeegz]

thanks aMaff.

I have threatened my car with murder over those two bottom bolts on the brace..

I think I need a different ratchet extension. ARGH! or fresh arms

 

[Breeegz]

oh and don't forget the f'n skito swarm I keep having to fight off or be carried away in the f'n Alaska midnight sun...

 

[Mike R]

Yes, the upper half comes out without pulling the lower half. It's a bit tricky, but I've done it twice. I still think the PG one is a waste of money, just do a VTCS removal and a little porting. Does wonders.

 

[Breeegz]

Yes, the upper half comes out without pulling the lower half. It's a bit tricky, but I've done it twice. I still think the PG one is a waste of money, just do a VTCS removal and a little porting. Does wonders.

got any of those "tricks" you can pass on?

 

[Breeegz]

Saw http://www.mazdas247.com/forum/showthread.php?t=123615599&highlight=issues+intake+manifold&page=3

gonna try it again..

still could use a couple pointers pulling off the upper half..

I took off the lower bolts on the brace, removed all the bolts (I have a spare going in so I've checked for hidden gems) and vacuum hoses.

I can't get the driver side to come loose, passenger side pops right off.. Did anyone else have this problem?

I'm about half a centimeter from getting it to come off, do I just need to use more force?