Replacing IM Gasket = Worst Job Ever

[Blurred Talon]

Had to replace the gasket on my Intake Manifold this weekend. This is simply the worst repair I've ever had to do, it's such a pain to get at the lower bolts with the huge hands I've got but luckily with a ratchet wrench, it's doable.
Starting the tear down, the night before. There's so much stuff to get out of the way first that I didn't finish it the first day.

Once I got everything out (power transistor, coil pack, fuel injectors and rail, throttle cable, etc). It was getting dark so I decided to stop working on the intake manifold for the day. I turned my attention to my throttle body. I wanted to block off my FIAV plus I plan to replace the TB shaft seals too and give it a good cleaning.

FIAV turned all the way in.

Freeze plug reinstalled and some vacuum caps on the unused ports.

Woke up this morning and after lots of fighting, off came the intake manifold.

I installed an EGR delete plate from RTM Racing.

New knock sensor.

Tapped the EGR port in the head and put in a 1/8NPT plug with lots of Lock Tite on it.

Slipped the new IM gasket on.

Then I started putting the manifold back on. My Dad came out and caught this picture of me working.

Finally done with the intake manifold and I hope I never have to touch the thing again.

Another weekend of wrenching and I'll be driving the car again.

 

[PieEyedPiper]

Classy action shot! haha!

How long did the whole process take, would you say?

 

[muscle187]

i just did the intake on a 420a and it kinda sucked got my hands stuck a few times but it wasn't too bad.

 

[Blurred Talon]

Classy action shot! haha!

How long did the whole process take, would you say?

All in all about 5 hours, I took my sweet time.

 

[phunny]

No wonder it was so hard for you, you have bear-paw-itis . My women has nice small hands and she can get to those bolts easy

 

[Fejery4491]

I had to do this exact job on my buddies Talon today. What a pain, plus it started raining as soon as I finished the teardown so I had to use a tarp and construct a makeshift tent haha.

 

[TJCTalon]

Man I just finished this job on my car. It was no funn and I did the exact same things you did. EGR block off and FIAV bypass plate. I had a spare manifold around so I ported it pressure washed it and painted it. There was space under the car to reach up between the downpipe and lower crossmember. Which made getting those bottom three bolts much easier to get to.

 

[Blurred Talon]

No wonder it was so hard for you, you have bear-paw-itis . My women has nice small hands and she can get to those bolts easy

Yea, the wifey wasn't with me so I couldn't even attempt to pass the job off.

I had to do this exact job on my buddies Talon today. What a pain, plus it started raining as soon as I finished the teardown so I had to use a tarp and construct a makeshift tent haha.

I feel your pain. I've had to rig up a tarp a couple times working on my car. I really want to build a garage so I can store the thing at home.

 

[gusu]

I see the rust monster paid you a visit. I LOVE your valve cover. The color mainly but I also really love the shave on it.

 

[Blurred Talon]

Thanks man!

I need to paint/clean up the brackets in the engine bay. I'd like to powder coat a bunch of stuff but I don't have anywhere to do it.

 

[boredog]

valve cover twins!

 

[Blurred Talon]

Purple is becoming too trendy. I wanted it for a while because I like bright colors, I wear orange slippers around the house hahaha.

I might change it when I do a proper catch can set up on the car. Maybe V-twin colors, orange and black.

 

[daren_p]

Should have swapped to an EvoIII intake mani, with the shorter runners, those lower bolts are much easier to get at

I just re-installed my evoIII intake the other day, took maybe 10 mins (granted the engine was on a stand )

 

[LiquidX]

Nice job, and it's good to see more people using the free FIAV block method

Hopefully since you blocked off your EGR you also thoroughly cleaned out the manifold of all the carbon and oil build up. That's the real gain in the block off.

 

[Blurred Talon]

Should have swapped to an EvoIII intake mani, with the shorter runners, those lower bolts are much easier to get at

I just re-installed my evoIII intake the other day, took maybe 10 mins (granted the engine was on a stand )

Cheater!
I have many more things to do before I switch manifolds on my car even the Evo 3 manifold. I need injectors, pump and FMIC next.

Nice job, and it's good to see more people using the free FIAV block method

Hopefully since you blocked off your EGR you also thoroughly cleaned out the manifold of all the carbon and oil build up. That's the real gain in the block off.

It's a great write up, thanks for making it easy to find.

My EGR has been blocked for for a while now but I still had the EGR valve in place.

 

[LiquidX]

No problem!

So it's safe to say it was cleaned out then?

 

[lastshark08]

Dang mine only took a half an hour tops in and out. i guess things are harder when your not doing in a shop

 

[Blurred Talon]

No problem!

So it's safe to say it was cleaned out then?

Yea, it was jet washed last time I had it off.

 

[livedsm4g63]

5 hours? Thats a lot of beer to go through

 

[habitatguy187]

No wonder it was so hard for you, you have bear-paw-itis . My women has nice small hands and she can get to those bolts easy

Sounds like Phunny's bragging about his "women"s ability to work with small bolts

 

[Blurred Talon]

5 hours? Thats a lot of beer to go through

, no beer was consumed while doing this repair. I drank a case the day before so I was at my limit for the weekend.

 

[richard5309]

i just did this today as well but now i have a serious vacuum leak somewhere

 

[ManticSHadow]

Makes me hungry for spaghetti in that bay but awesome work!

 

[Blurred Talon]

^.
The joys of the stock engine bay, not to mention I've added a couple things.

 

[ElectronVTEC]

I just did the same job yesterday, took about 4 hours swapping to an EVO III IM and yes, it is a million times easier to get at everything now. With that said, I lucked out and found an extended-length 12mm box combination wrench in my toolbox, that thing worked like a charm, in conjunction with a stubby 12mm for spinning off everything but the last lower bolt. Definitely not something I want to do again anytime soon though.

Todd