DIY 4g93T GDI INTAKE MANIFOLD REMOVAL AND CLEAN
Posted: August 2nd, 2012, 5:36 pm
OKAY HAD A DAY OFF DECIDED TO ATTEMPT THIS.
okay there is the intake manifold with coilpacks on top and head studs holding down the intake.
remove the coilpacks have 2 {10} bolts on each coilpack. after removal of the the coilparks there are 7 {12} bolts, 4 on top and 3 below where the coilpacks were. remove these to free the intake on the engine block, rememeber where the bolt comes from becuase as u can see there are 4 groundin wires on 2 of the bolts for the coilpack
heres the hardest part didnt take out any picts but will give u the run down.....
jack up the car becuase there are bolts that ive tried to remove from the top and nothin, since these dam engine have no hand space best place was underneath
under the car go to the back of the intake right underneath ull see 2 {12} bolts that holds the bottom of the intake , it maybe hidden by the alternator wire running to the battery. remove them fairly simple.
as u look directly under the throttle body ull see a water line running to a valve, its like a diamond shape with curves silver plate with 2 {12} bolts , this is the egr valve , u have to remove these bolts also. let me say these were the worst 2 bolts to remove in this whole thing. advise use a long extension and ratchet. when u get these out have to come back to the top of the engine
now to the throttle body , there are 4 {12} bolts, before even reaching this u have to remove the intake hose on the throttle body and also the battery for a reason...
when u finish this u should see the throttle body bolts. remove them but be careful. there is a gasket between the intake manifold and throttle body so when u unscrew this will slip out .
so i removed the these bolts and thought the intake would come off but there are sensors to which i dont know to much about to remove.
on the brake booster side of the engine, there is a vacuum line that has to be removed,
also the PCV valve on top the manifold on the left has to be removed. on my engine it had 2 jacks to remove running over the manifold towards the alternator area. removed them
on the throttle body side now, there are 2 jacks directly on top the throttle body that is attached by clips on the manifold, these have to be removed. there is also a vacuum hose on the the throttle body facing the firewall , remove that.
ok all the sensors and hoses were removed.
but not for nothin the intake manifold was coming out.
till i realise the throttle body although the bolts was off was preventing the manifold from moving.
the top of the manifold was ready to come off but wasnt coming off.
but realised there is a bracket that holding the throttle body in place. this bracket is has a ring on top which is used to remove the engine with a cherry picker.
there are 3 {12} bolts on this bracket to be removed. 2 hiding close by the recirculating valve area. remove the battery otherwise u wont see them. i didnt remove the bracket just pushed it and the throttle move away from the intake manifold and the gasket fell off.
the intake manifold popped out.
as rollingstock and xtech said . FLICKING CARBON BUILD UP LIKE WOW.
EGR VALVE
THIS THE INTAKE MANIFOLD THAT RESTS ON THE BLOCK , AS U CAN SEE THERE ARE LITTLE RUBBER GASKETS ON THEM , REMOVE THEM BEFORE WASHING THE INTAKE DONT WANT TO BURST THEM.
INSIDE THE INTAKE
okay there is the intake manifold with coilpacks on top and head studs holding down the intake.
remove the coilpacks have 2 {10} bolts on each coilpack. after removal of the the coilparks there are 7 {12} bolts, 4 on top and 3 below where the coilpacks were. remove these to free the intake on the engine block, rememeber where the bolt comes from becuase as u can see there are 4 groundin wires on 2 of the bolts for the coilpack
heres the hardest part didnt take out any picts but will give u the run down.....
jack up the car becuase there are bolts that ive tried to remove from the top and nothin, since these dam engine have no hand space best place was underneath
under the car go to the back of the intake right underneath ull see 2 {12} bolts that holds the bottom of the intake , it maybe hidden by the alternator wire running to the battery. remove them fairly simple.
as u look directly under the throttle body ull see a water line running to a valve, its like a diamond shape with curves silver plate with 2 {12} bolts , this is the egr valve , u have to remove these bolts also. let me say these were the worst 2 bolts to remove in this whole thing. advise use a long extension and ratchet. when u get these out have to come back to the top of the engine
now to the throttle body , there are 4 {12} bolts, before even reaching this u have to remove the intake hose on the throttle body and also the battery for a reason...
when u finish this u should see the throttle body bolts. remove them but be careful. there is a gasket between the intake manifold and throttle body so when u unscrew this will slip out .
so i removed the these bolts and thought the intake would come off but there are sensors to which i dont know to much about to remove.
on the brake booster side of the engine, there is a vacuum line that has to be removed,
also the PCV valve on top the manifold on the left has to be removed. on my engine it had 2 jacks to remove running over the manifold towards the alternator area. removed them
on the throttle body side now, there are 2 jacks directly on top the throttle body that is attached by clips on the manifold, these have to be removed. there is also a vacuum hose on the the throttle body facing the firewall , remove that.
ok all the sensors and hoses were removed.
but not for nothin the intake manifold was coming out.
till i realise the throttle body although the bolts was off was preventing the manifold from moving.
the top of the manifold was ready to come off but wasnt coming off.
but realised there is a bracket that holding the throttle body in place. this bracket is has a ring on top which is used to remove the engine with a cherry picker.
there are 3 {12} bolts on this bracket to be removed. 2 hiding close by the recirculating valve area. remove the battery otherwise u wont see them. i didnt remove the bracket just pushed it and the throttle move away from the intake manifold and the gasket fell off.
the intake manifold popped out.
as rollingstock and xtech said . FLICKING CARBON BUILD UP LIKE WOW.
EGR VALVE
THIS THE INTAKE MANIFOLD THAT RESTS ON THE BLOCK , AS U CAN SEE THERE ARE LITTLE RUBBER GASKETS ON THEM , REMOVE THEM BEFORE WASHING THE INTAKE DONT WANT TO BURST THEM.
INSIDE THE INTAKE
