Newbie needs help for intake manifold removal

[Peterdemon]

Hi guys, been lurking around the forum for some while. It's time for my first post.

Earlier today, I was trying to remove the intake manifold (yep, you guessed right, screws from the vics in two cylinders). It was going well until I had to remove the manifold. I am trying to remove the top half only and leave the bottom half in while I change and apply loctite on the famous screws.

So, when I tried removing the top half, the drivers side of the top half wouldn't budge. The passenger side is alright.
Haven't removed the throttle body and EGR valve since I didn't think it's necessary.

Any ideas? Should i remove the whole manifold instead?
I'm gonna try again tomorrow. Too dark to work (unfortunately, no garage).

any input is appreciated(thumb)

 

[fishdonotbounce]

I feel your pain. It's kind of sad but I can remove the entire intake mani in 20 minutes now without a problem. Just remove the whole thing. One thing that's going to suck is the EGR pipe. If you can somehow get down at the nut holding in place and get it off, your life will get a lot easier. Otherwise, you're going to have to diconnect all the coolant lines and everything else that are in the pipe's way, and maneuver the mani out with the pipe attached. I wish you the best of luck and if you have any more questions, feel free to ask.

 

[i12drivemyMP5]

Loosen the brace that goes from the side of the motor to the intake so you can get the upper half worked free.

 

[Peterdemon]

@ fishdonotbounce: 20 mins to remove it! are you serious? I've spent 4-5 hours so far! even the mazda dealer asked for a minimum of 2.5 hours!

Loosen the brace that goes from the side of the motor to the intake so you can get the upper half worked free.

didn't mention it but I did that too.

I guess I'll do it the long way: remove the throttle body, egr valve and take the whole thing...

so i'm gonna have to drain the engine coolant, right? so what coolant do I have to put back in? also 50/50 mix of distilled water?

 

[fishdonotbounce]

@ fishdonotbounce: 20 mins to remove it! are you serious? I've spent 4-5 hours so far! even the mazda dealer asked for a minimum of 2.5 hours!



didn't mention it but I did that too.

I guess I'll do it the long way: remove the throttle body, egr valve and take the whole thing...

so i'm gonna have to drain the engine coolant, right? so what coolant do I have to put back in? also 50/50 mix of distilled water?

haha yea 20 mins. The first time it took me 5 hours. THen I swapped mine with one that was port and polished. Then I had a coolant hose burst on me (coolant feed for turbo) and I had to take it off. All together, I've taken it on and off at least 6 times by now. But like I said, if you need any help, let me know and I'll do my best to help you.

 

[dacquesta1]

do it enough times and its second nature...gotta love repetition.

 

[eszoom]

i was looking to do this soon, but after reading this.. at least 2 guys i've read that took 4-6 hrs... thats too much for me.

 

[dacquesta1]

the intake manifold is an easy job...just gotta take off your intake pipes, coolant lines to the throttle body, fuel rail and the intake manifold brace. theres 5 bolts and 2 studs holding the manifold on. its not too bad.

edit: and egr pipe...enjoy that lol

 

[Peterdemon]

Well, i took my sweet time, labeling things, to be sure that i can reinstall everything the right way.

i was looking to do this soon, but after reading this.. at least 2 guys i've read that took 4-6 hrs... thats too much for me.

 

[Peterdemon]

and also, what's special about the egr pipe? i don't get that (uhm)

 

[JCell]

haha yea 20 mins. The first time it took me 5 hours. THen I swapped mine with one that was port and polished. Then I had a coolant hose burst on me (coolant feed for turbo) and I had to take it off. All together, I've taken it on and off at least 6 times by now. But like I said, if you need any help, let me know and I'll do my best to help you.

same boat, once u know how to do and what to look for it really is not difficult.

 

[fishdonotbounce]

and also, what's special about the egr pipe? i don't get that (uhm)

The EGR pipe is the copper pipe that is attached to the driver's side of the intake manifold right underneath the throttle body. It is damn near impossible to get a wrench in there to loosen the bolt and if the bolt hasn't been loosened before, it is better to pull the intake manifold out with the pipe attached to intake mani. You need to disconnect the other end of the pipe at the exhaust manifold and then pull the intake mani and pipe out as one piece. This causes you to have to disconnect a few coolant lines and other stuff so that you can maneuever the two pieces as one out of the engine bay. That's why it's a pain in the balls.

 

[reut1]

when youre doing this and disconnecting coolant lines, does this mean drain the coolant from the car and youre unscrewing the lines or just popping them off from their mounting locations.

 

[fishdonotbounce]

draining the system I found does nothing since that coolant is already trapped in the back there. I just disconnect the lines and make a big ass mess. I upgraded to using plastic cups last time I did it to catch some of the coolant but usually I just end up spilling it everywhere.

 

[Peterdemon]

at last, i was able to remove the top halve only (cool). the egr pipe was limiting the movement of the bottom half on the drivers side. but that doesn't end there.

i took a look at the famous VICS and then WTF!!! the valve for cyl #4 is completely missing! not only those 2 screws but the round piece of metal is missing! (omg)

what should i do now? i know I heard sound like coins in a dryer the last time i started the engine and, a month ago, the #4 spark plug got squashed. can it be physically possible for that chunk of metal to go in the cylinder? am i gonna have to remove the head and check to be sure?

 

[Peterdemon]

here, a picture is worth a 1000 words

 

[fishdonotbounce]

It is possible for it to have broken up and entered you pistons. It happened to djdub and it squashed a few of his plugs too. I hate to say it, but it might be time to tear it down. Before you do, try to check inside of the bottom half to see if it may still be in there.

 

[Peterdemon]

i just checked the bottom half. didn't completely remove it because of the egr pipe but simply shook it and it seems like nothing is in there...

 

[fishdonotbounce]

I dunno what to tell you my friend. Pull the head.

 

[Peterdemon]

do you mean the cylinder head? is it possible for me to take out? or should i let a real mechanic do it?

by the way, thanks for all your help so far