intake manifold removal

D

dbcopper

Registered
OK, am I right? I found another thread in these forums that substantiates my belief that the inlet manifold can only be removed by tiny people who live under the hood and drink gasoline. I have a vacuum leak in the area of the manifold gasket and fully believed that as a former mechanic with a shop full of Snap-On, I would not be driven to drink over anything on my '96 Mark 8. I was wrong and I'm drinking. Any new information from anybody who has met this challenge before would be much appreciated. Don't send me your dynamite theory, I've already considered that! It seems that pulling the engine may be easier, but that cannot be true ........ can it???

I have the manifold loose and ready to lift off except for that tube running to the exhaust (I presume) which has no visible disconnection point ... could be that this chassis, originally designed for a V6, has finally shown me why that is true.

Any tips will be greeted with enthusiasm.
Thanks, dbcopper
 
When I swapped mine out, the EGR tube was disconnected since I had headers.

Besides the obvious, be sure to remove the wiper assembly and plastic cowl.

Unbolt the EGR valve leaving it and the tube behind.

Have you removed the alternator and front crossover tube?

You basically lift the manifold and move it forward enough to disconnect everything at the rear, then slide it forward out from under the engine wiring harness. Leave the IMRCs bolted to the manifold with the smaller bolts as well as the fuel manifold.

Do you have the torque procedure for the re-install?
 
EGR is the problem

EGR is the problem

Your comment was good for a chuckle at this end, "unbolt the EGR valve", you said that like it was easy ... it ain't easy and not even accessible. Yes the alternator is out, cowling removed and all else is ready to go. The EGR is the whole problem and unless you are supposed to lay across the engine and unscrew bolts or nuts you cannot see, I have no idea what to do. Pulling the engine seems more likely than reaching those fasteners. Have you ever had to actually remove one of these on a stock car? If headers are installed, you may never have seen the mess that I am looking at. Appreciate the comments and solicit others from you or anybody else who can help.
 
my egr tube was cracked(driller diagnosed from me getting exhaust oder w/sunroof tilted)my car has the stock exhaust manifolds. I removed the wiper motor and plastic cowling and used 1/4 drive ratchet w/wobble socket P.T.A.and took a couple beers to finish project..... a small mirror helps! driller mentioned sliding the manifold ahead that has to help!!! the more room the marrier! carefull the old tubes seem fragile from heat and time.
 
dbcopper said:
Your comment was good for a chuckle at this end, "unbolt the EGR valve", you said that like it was easy ... it ain't easy and not even accessible.
Click to expand...

It is accessible. Remove the wiper/cowl assembly. I think I remember the bolts needing a 10mm socket. Yes a universal joint helps too. Trust me, I know your pain, these big old driller hands aren't as nimble as they used to be. My car has eaten more sockets and tools than I care to remember. LOL :D
 
enough with the cowl assembly

enough with the cowl assembly

That's like lifting the hood to get at the main bearings. You can do it and it helps, but that is not the problem. With the cowl in the other room, you still can not get at these things in any reasonable fashion. I'll bet there are hordes of Ford Engineers reading this thread and laughing their collective butts off.

I have enough input by now to realize that there is no easy way and it must be a real joy to get those bolts back in. Thanks to everybody for contributing. I may be another year older, when I get these things out, but I will get 'em!
 
If you think the EGR is bad you best get a new IACV and put it on while the intake manifold is out. :)
 
Don't do this. Please !!!!

Removing the manifold in order to get at the snapped EGR bolt was the very first thing I ever did to a mark viii, back in 2000, and it's the exact thing that started this never ending M8 madness :mad: :D :D :D
 
It's 1 1/4 and 1 1/8 for the bolt sizes. You removed the two plastic pieces that cover the wiper motor, but did you unhook and remove the third piece with the motor also? Ok good stuff your next step is to spray the crap out of both end with pbr. Then remove :) Oh, you can take the DPFE off also it usually goes right above where the clip is in picture 1.
 

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I am amazed that you even got those images. I can't see that much, what did you do, remove the car from the engine? I am on my third "special" tool right now, waiting for the heat to dissipate from the bent 1/2" steel bar before silver soldering a 10mm socket to the end of it. Next is dynamite, photos of that event to follow if it sticks the landing. I think I will go into the business of making tools for this process. Should be able to sell six or eight of them. At $10 grand apiece they would be a bargain. I am closing in on a solution and will post pics and results in time. Thanks for the effort you made here on my behalf. dbcopper
 
I had to remove the EGR tube to replace it once. I just removed the big fitting nut at the valve.

I disconnected the hood struts and propped the hood up higher for a lot more room. Don't open it too high, or the corners will touch and bend.
 
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