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Old 06-01-2012, 07:07 PM
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Q about intake manifold removal.

So one of these weekends I plan on removing my intake manifold, cleaning it and doing a EGR delete by welding freeze plugs in the cooler (emission purposes) Ive read the service manual and they say you have to take out the oil filter housing and a bunch of stuff. My question to those who have done it how difficult is it? I know I will have to remove the turbo, but it looks like just unbolting the manifold from there and not much else. Oh and should I drain the coolant, or will it be easier to loose some and just add it when done? Any tips and advice are appreciated.
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Old 06-01-2012, 07:11 PM
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Drain some coolant, remove the turbo, remove the oil and fuel filter cans, unplug injector harness, unbolt egr cooler, remove intake manifold.
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Old 06-01-2012, 07:20 PM
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Dang, so the fuel and oil filter housing both have to come out huh? Oh well I guess just a few min of extra work. My truck is currently in the shop so I cant look at if for reference but I will take your word Mitch, thank you.
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Old 06-02-2012, 06:20 AM
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The fuel and oil filter housings are a one piece casting. Take 4 or 5 (I can't remember the exact number) of bolts holding the cans to the base and they come right out as a single piece. The oil can seals to the base with an o-ring. It is trivial and takes less than 5 minutes. It takes longer to disconnect the fuel lines from the can. Make sure to put some wire ties around the fuel lines so the nuts don't slide down the lines. they are a PITA to get back up when that happens.

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Old 06-02-2012, 08:05 AM
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This would be a great time to address your oil cooler if needed. I recently just did the same procedure to my '03 and I was amazed how much crap was in the intake. It took alot of time to get it clean. I also removed the exhaust housing on the turbo and clean the rust and coking that was on the surfaces where the vanes pivot. This made a big difference in turbo spool up time.
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