motocrossaddict223

so my intake manifold got cracked blah blah blah but i got a new one now my issue is it still will not come off. i have taken everything off the fuel rail the injectors everything. I have checked that the 12 bolts and 4 nuts were off so many times. What could be holding it on!? I really need your guys' help on this, everywhere i look it says it just slides right off! what am i doing wrong!?

MudHippy

If you've taken everything else off, including the NO.2 idler pulley and the water by-pass outlet, then you should be able to lift it up out of there fairly easily. Sometimes the gaskets get stuck to the heads and the intake manifold real good, so you have to "break" that seal. But it shouldn't take too much effort though. Just grab each end of it and jerk upward on it with a medium force. It'll come off...

motocrossaddict223

well i got my hammer pull and i got almost all of it off but the back passenger guide stud seems to be seized of the manifold so i cant get if off..if i lift the front up, the studs just bend. any suggestions?

Turd Furgeson

Did you get the allen head bolt by the thermostat housing?

MudHippy

Well...ain't that a bitch?

Huh...

I don't know. I was thinking just unscrew that stud from the head. But there's not a whole lot of stud to grab hold of IIRC. So that might not work for that reason, or because of it being seized to the intake manifold.

I might try sticking a long piece of wood(broom handle, hammer handle, dowel, etc.) down the intake runner closest to the firewall. Then using it as a lever to pry the intake manifold towards the driver's side, with the driver's side head as the fulcrum/pivot point. But keeping in mind that you wouldn't want to tilt the intake manifold too far, and possibly damage the mating surfaces on it or the head. The gasket on that side would be smashed in the process, but also act as a buffer/shock absorber protecting the two parts from being messed up...to an extent. Meaning I wouldn't be using the technique to gain more than a few mm of movement(by the intake manifold in relation to the stud). From there you might be able to slip something to pry with under that corner of the intake manifold and pry it the rest of the way off.

If it won't budge at all, try gently tapping on and around the stud with a brass drift pin to try and loosen any corrosion(or whatever is causing it to seize to the intake manifold). Then try some more tugging/pulling/prying. If that didn't work, then I might apply a little heat(propane torch). Then more tugging/pulling/prying.

If none of that works, try soaking the stud/hole with penetrating oil(WD-40) overnight. Then give 'er another round or two of heavin' the next day.

Good luck!

Umm...wrong engine.

motocrossaddict223

oo i have beat the hell out of that thing but havent tried prying by the intake port...where is this allen bolt? neither of my manuals have said anything about an allen head and i didnt use an allen anywhere?...if i havent already said i have the 3vze

MudHippy

There's no allen bolt. I'm pretty sure he means the 22R-E.

Anyways, just be careful if you do try prying on it. The more I think about it, the worse that idea sounds. But who knows? It might work...

Hard to believe you can't get 'er off with a slide hammer. That sucker must be stuck in there GOOD!!! What a PITA eh? Seems like there's ALWAYS SOMETHING making you wanna when you're working on a vehicle.

EDIT: If all else fails you might have to very carefully drill out that stud w/o trashing the threads in the head in the process. Last resort, of course. Real easy to end up with an open can of worms on your hands going that route. Because I'm not sure if drilling/tapping the hole bigger and using a bigger stud would even be feasible. Maybe?

motocrossaddict223

yea i thought he meant the 22re..but im not too concerned about the manifold mines cracked so ive got a new (to me) one anyway. I'm not sure what to do do im going to go drown it in pb blaster in an hour or so and tomorrow after work go back to beating the piss out of it. I'm not sure what else to do, i've even tried talking dirty to her and still nothing.

Turd Furgeson

Yeah,sorry,I thought you had a 22re.

motocrossaddict223

well guys i finally got it off, now the back passenger side stud is messed up but i think i can still salvage it. It only took sitting it pb blaster and freeze off and industrial spray lube to get it off but hey its still off. Also which way does the knock sensor go under that pipe in the valley or over..i forgot which way mine was.

MudHippy

You can probably find a stud to replace it pretty easily, if you have to.

The KS wire goes over that pipe.

motocrossaddict223

of course it does well i put it under. As far as the stud goes i just bent it straight ish and got the manifold on. but now i have to work on my 5 speed swap

vital22re

iTrader: (2)

I hope you replaced that wire. The are very common to fail. And you know how much work it was to pull it apart once.

motocrossaddict223

o yea i did thats the whole reason i was in there.
now all i need to find are these two spacer things (circled in yellow)


heres where im at right now almost done

MudHippy

Honestly, I'm not sure if it even matters. All the pics you'll find if you google it, show the wire going over it. And I'm pretty sure that's how mine was when I took it apart the first time. Which may or may not have been the first time the intake manifold had ever been removed. It appeared the first time, but I can't say for sure.

motocrossaddict223

well looking at pictures i took and how the wire was bent it went under but hopefully it doesnt matter. But either way its done now so o well.