Lower Intake Manifold Removal

Topic: Lower Intake Manifold Removal (Read 1433 times) previous topic - next topic

Lower Intake Manifold Removal

July 31, 2006, 02:10:43 AM

what did I get myself into. This is far more complicated then just the removal of the upper.

Ok.. here is my plans. Since of the broken thermostat bolt I want to upgrade to gt40, explorer or cobra upper/lower manifolds and since I'm this far I'll do some other stuff to the engine to free up some horsies.

Right now I have the fuel injectors disconnected but I think I screwed a few of those up. Seems like the heads of the bottom of the injectors are still lodged within the intake after I pulled them from the manifold. (umm that can't be good)

I really really think since I'm this far I should just pitch the smog, a/c, and get the electric fan w/ the alternator upgrade. Basically everything in my engine bay right now is all over the place. Every hose tube sensor plug is disconnected. I feel that I'm over my head with what to do next but I can only learn from this. So Nick I might be needing your advice or help over the phone again much like last year. haha.

Anyone know of any good sites for mustang disasembly, how to dvds or videos. Basically what I'm asking is that really I have a basic understanding of my car. But when it comes to the wrench time I'm a beginner. If I was able to watch another person on tv or something maybe I'll be better off. I have no help from anyone since everyone in my town putts around in their rice shooters and want nothing to do with a ford v8.

Any recommendations that I should do while removing the intake? Am I able to change the heads out without removing the block from the car? I'm really looking into the cobra intakes on summitracing.com I really like the looks of them and the price isn't too bad.

Lower Intake Manifold Removal

Reply #1 – July 31, 2006, 08:13:42 AM

I wouldn't take anything off the lower till you have both lower intakes side by side on the bench. By anything I mean all the sensors, injectors, pipes.. etc

Basically to remove the lower you need to:
-disconnect all the sensors and injectors
-take off the upper (your done that :) )
-take all the bolts out of the lower
-Remove the upper radiator hose
-Mark your distributer inside and outside and remove it (you might be able to do with distributer in but i like to have the room and its only one little bolt holding it in
-disconnect all coolant lines from the heater core BE CAREFUL IF THEY ARE HARD TO PULL OFF JUST CUT THEM AND REPLACE THE HOSES. I PULLED TOO HARD ON MINE AND PULLED THE TUBE RIGHT OUT OF THE HEATER CORE!
-you need a tool to disconnect the fuel lines from the body lines

This should get you started.. its all that I remember without looking at it. I'm sure I left out something, but nothing that you cannot see

Lower Intake Manifold Removal

Reply #2 – July 31, 2006, 08:55:13 AM

Hopefully you tagged the connectors before you disconnected them so you know where they go. If you didn't, it shouldn't be too difficult to differentiate the locations of the connectors. You can usually tell by the curve the wire has in it (from sitting in it's specific position for the past 18 years) where it connects.

Like thunder306 said, don't remove any of the sensors from the intake until it is off the car and you have the new one next to you. You can remove the injectors. I left mine connected to the fuel rail and just moved it off to the side.

If you go the route of the cobra intake, you will need to make sure you put a plug in the back of the lower manifold where there is a provision in the standard lower for antifreeze flow to the spacer plate. You will also need to plug the provision that runs coolant into the spacer which is on the black metal coolant tube that runs along the passenger side of the engine.
That tube was a pita for me to remove to put on the new manifold so it helps to have a pipe or something so you can torque it out.

It is not necessary to remove the distributor. You can finagle the intake out. It is not too easy but it is possible.

My injectors did the same thing. I saw that some had cracks and whatnot so I just replaced them all. That was the most expensive thing about this entire deal for me. Maybe I didn't have to replace them but I just thought it would be best.

You can change the heads while the motor is in the car. It isn't too difficult.

Sorry Steve, If I was closer to you, I'd be over to help.
I had way more problems than I should have but it really isn't too bad.
Just spray whatever bolt you need to remove with liquid wrench, that stuff works wonders, trust me.

I don't know of anything that gives a step by step for this but I went on the public library's website. They had a auto repair reference data base where I looked up my car and a '93 mustang cobra to get the proper tear down/assembly procedure as well as the proper torque settings.

Here is a picture from when I did the swap...
I know this pic is small, I can't enlarge it on this computer but it is on page 4 of my cardomain where it can be enlarged.

Lower Intake Manifold Removal

Reply #3 – July 31, 2006, 10:21:25 AM

Those plastic hats like to stick in there. Once it is off just poke them out from the bottom side. I've had to do that with my 2.3t lower intake. Also you might want to replace the orings. Not the expensive at the parts store.

Lower Intake Manifold Removal

Reply #4 – July 31, 2006, 01:15:26 PM

Those plastic "caps" on the injectors are the pintle caps, and you don't actually even need those. They really just keep the end of the injector from getting damaged. I don't believe any of the injectors on my car right now have the pintle caps on them.

Lower Intake Manifold Removal

Reply #5 – July 31, 2006, 03:10:49 PM

It won't be as hard as you think, Steve. I did this twice within 2 weeks on my Grand Marquis (basically the same) and it's really pretty fool proof. The injector harness pretty much won't let you plug them in in the wrong order, and all of the sensor plugs are pretty unique to the sensors they attach to.

Lower Intake Manifold Removal

Reply #6 – July 31, 2006, 05:47:41 PM

Man, this brings back memories. It's a good thing you won't run out of time like I did!

I found this article very helpful:
http://www.allfordmustangs.com/techarticles/headcamintakeswap.pdf

It looks like you may as well do the heads so you wouldn't have to remove your lower intake again.

Here's some other tips I picked up while searching around the mustang boards:

- the 5th bolt away from you on the passenger side should be removed last, since it holds the coolant tube onto the lower intake and will probably just spin freely when loosened.
- be sure to get the Fel Pro lower intake gasket set since it includes the nice, form-fitting plastic front and rear seals. Don't use those cork ones.
- you don't need to remove the fuel lines (thank goodness, because stupid me bought the wrong size disconnect tool).
- cover the O-rings lightly with vaseline/dielectric grease when you put the injectors back in, it will help if you ever need to get them out again.
- after torquing the lower intake bolts, wait 24 hours and torque them again.

I hope you have better luck than I did! :bricks1:

Lower Intake Manifold Removal

Reply #7 – July 31, 2006, 06:30:45 PM

When Your ready to drop the new lower on. Get 4 studs and put them in the corners into the heads to guide down the lower. This tip really helps when your doing it without a helper cause its a pain to try and line up the lower when your stretching over the car.Also the lower position will be perfect and You don't have to worry about the front and rear leaking from moving it around.

Lower Intake Manifold Removal

Reply #8 – July 31, 2006, 06:38:54 PM

It also would be wise to get a new set of bolts, which are easy to find, to bolt the lower intake on. Most likely your original bolts are weak and may break when you torque them. Mine were horrible, one broke while trying to remove it and many were quite deformed.
It's cheap insurance.

Lower Intake Manifold Removal

Reply #9 – July 31, 2006, 06:48:38 PM

You can also substitue wooden dowels for the studs in the corners.

PS - Those help a LOT.

Lower Intake Manifold Removal

Reply #10 – August 01, 2006, 04:11:34 PM

wow guys all great tips!
THanks a million. Finally got the saab towed to the garage yesterday. Fuel pump is what I believe to be the problem. Maybe next check I'll get the cobra intake... we'll see. Thanks :)