Alright, all the nuts are loosened and the intake is about to come free, have all the vaccum lines, wiring harness, and most other stuff pulled from it. All I have left are two things. Well maybe three.

Anyway the EGR Tube I still need to undo. It seems like the only nut I can even get a wrench around is the upper one and its a 15/16 wrench. Is that all you need is to just loosen that one? Ive sprayed the thing down with Liquid Wrench and PB Blaster, started hitting at it to help loosen, then sprayed it more. So well see.

Also the other thing is the Turbos Air Inlet tube that goes back into the throttle body, throttle chamber, whatever you want to call it. Is it just the clamp holding it on? I loosened the clamp, but it doesnt want to seem to budge. Any last few tips?

Oh and Im not sure if this is neccesary, but it seems like the intake heat shield will get caught on the thermostat housing, do I need to remove this, or should the intake be able to slide up enough and then move over to work its way around?

 

its just clamped to the TB in its own unique way..... aka a rubber inner and the metal around it bends and clamps so youll prolly have to wiggle it alot to free it up, then it should come right off.

 

Yup wiggle it free...that clamp is all that's holding it together. As for the EGR tube and taking the intake off you're on the right track...that's what I would do. It does take a bit of manuvering to get that intake out. It shouldn't be too hard, just take your time.

 

OR.... you can eliminate the EGR like i did, F that stuff. lol. that EGR tube is ON TIGHT trust me, i had to remove mine with a firggin pipe wrench. its crazy tight.

 

So I hear. I wouldn't mind eliminating the EGR. Give me a heads up on a good way to do that, oh and before I get retarded and do this again. I'm trying to figure out which way I've got to turn it. Like I was thinking about it and normally I'd put the wrench on it and then pull it towards the firewall rather than away from the firewall, but then I thought is it like an upside down bolt that I'd be turning the other way? I end up going stupid enough and tightening things when I should be loosening.

 

ummm... well what i did for a temporary elimination until i can make block off plates or get an N42 intake, i smashed a pop can bolted it under the EGR solonoid, then cut teh pipe below it in the middle, and rolled the pipe over its self multiple times so it wont leak, but you can easily find bolts that will fit into those threads and just put them in, i was just feelin lazy.

 

I only need to loosen the upper nut on the EGR Tube right? Or do I have to get a wrench on both nuts?

 

no just teh one on the intake ... no reall need to remove both unless your gonna eliminate it.

 

Alright a few last questions while I'm still trying to mess with this crap. For the EGR I took some quick pics just to make sure I get this right and don't make this crap harder for myself. Sorry for sounding like such a noob here, but I really don't want to mess up more crap than I have to.

For the EGR tube which nut do I have to go after or does it matter? I've only been able to get a wrench around the upper one.


Just so I'm not being an idiot the wrench goes this way: <----------- Right?


Finally for the throttle rod, there's that little spot where there's like a spring and that hairpin. How do I go about getting that hairpin out without breaking it?

 

The hairpin (cotter pin) very carefully, but if you break it don't worry Ace hardware has some, or an autoparts store...I've borken it before. As for the EGR tube...the nut on the tube is what you want to spin. I used a cresent wrench. And if my memory is correct I pulled away from the firewall. I sometimes gets this mixed up as well...but I pull back and forth to help get some movement. It looks like you got this saturated pretty good. I used a pipe plug to plug the EGR hole on the intake. I wish I could tell you what size...I don't remember.

 

I think I may just join in and plug off the EGR. From what I can tell there's really no disadvantage of getting rid of the EGR system. Are there any advantages? I also read a thread somewhere saying that once you pull the exhaust manifold you should get it resurfaced?

I'm about ready to take a hacksaw to the EGR tube...

 

there is one disadvantage, you need to let the car war up in cold weather situations.

 

Alright after spending far too long trying to remove the damn EGR tube nut, I grabbed the hacksaw and cut it off in about 5-10 minutes. So all that's left is trying to loosen the turbo inlet tube. Will that come off with the manifold still in place, or do I need to get the manifold up and out? The thing is about to come out, but it's like it's still not quite there, might need to loosen one of the nuts a little more.

 

ummm... no need to remove the mani to get that out, but it might make it easier, remove the J pipe and you should be able to get at it just fine then.

 

Finally, I got the damn intake out. Now everything should hopefully go more smoothly. Loosened the clamp for the J pipe down by the turbo and just started pulling and prying and sure enough the whole intake came up and out. At this point no more EGR for me, unless I can someway get it out of the intake and downpipe and get a new tube.

 

Nice work!!

 

Thanks for all the help guys. All I have left to ask is, what's a good way to go about plugging the EGR? Since the tube is still connected at both ends, just seperated because I cut it. Would it be a good idea to work on getting the tube off the intake side and then just plug it, but what did you guys do for where the tube comes off the Turbo downpipe?

 

In my case I made a custom downpipe...2.5 inch mandrel bend. As for the intake side I plugged it...but I cannot remember what the pipe plug size was...I know it's less than 1" because that I know is what I used to plug off the pop off valve.

 

while you got teh intake off, go around to places you know have bolts and other accesseries and jsut see what fits.

 

Oh by the way. I see that almost everyone seems to switch to studs upon getting the intake and exhaust manifolds out. I got a set of the nuts/studs from Pallnet. Is that all I need? I won't need the huge washers that came off the bolts? Also I'm just curious as to why studs are better? Just because the nut is separate unlike the head of a bolt?

 

i dont know if they are better... i kinda like bolts cause studs (for me anyways) seem to break easier.... much.... other wise use the washer they help keep stuff tight equally.

 

Alright, I have a problem. This is the last thing I need to remove and then the exhaust manifold and all can come out. I can't remove the 3 nuts that connect the Turbo's down pipe. They look like they have teeth on them or something, and I'm not sure what to do. I have an impact wrench that I borrowed, but I'm not making progress.

 

PB blast them, let em sit, do it again, then try liquid wrench and then the impact gun, if no go, you can also remove the down pipe from the turbo, or remove the turbo from the exhaust manifold, you got 3 options. you can also try heating up the nuts with a blow torch then impact gun them.

 

Well I went back outside, and worked on getting the nuts off. No go with the impact wrench, felt like it was spinning or something. So I got a wrench a big extension, and my jack handle. Well it started turning, then just broke off the nut with part of the stud. So I tried the other two and same thing. Broke. I don't know if this will cause a big problem, but I'm beginning to think I may as well just go ahead and get a custom downpipe made. At least that way I can eliminate the EGR from the downpipe and just plug the EGR at the intake. Can pretty much any exhaust shop make me a downpipe? Also I was curious, what are the chances of the bolts breaking that hold that downpipe to the turbo if I were to try and remove them?

 

ummmm.... probably not as good as teh downpipe piece but VERY possible. its no real big, you drill wem out and re tap them. its bes you do that anyways and replace them with SS ones they wont go shitty on you. just work VERY slow when initially breaking tehm free... and PB blast teh ***** out of them let em sit a half hour and try then