removing intake manifold.

Danno · Post by **Danno** » Sat Feb 25, 2006 4:09 pm

any advice for getting this thing off WITHOUT removing the whole stinking engine? I got one nut off but the one closest to the firewall is impossible to get at! Just trying to get rif of the old so when my new gets here I can run with it!

Danno · Post by **Danno** » Sat Feb 25, 2006 6:23 pm

ok, two nuts removed. apparently there are 4 more bolts now. as I look in my manual, this is NOT what my intake looks like. their 4 bolts appear to be on the top. Are mine underneath?

Danno · Post by **Danno** » Sat Feb 25, 2006 6:44 pm

ahha! I knew it. they ARE underneath. how the heck am I to get at those? there isn't even enough room all the way around that bolt to fit a socket!

and here's a nice pic with the carb gone....

Danno · Post by **Danno** » Sat Feb 25, 2006 7:31 pm

ok, can I remove the engine mount bolt on the driver's side and jack (using the oil pan?) the engine enough to get in there? Seriously. everyone talks about this being easy, so surely someone has run across this before. I checked miafiori and fiatcenter and didn't come up with anything

mdrburchette · Post by **mdrburchette** » Sat Feb 25, 2006 8:18 pm

Welcome to Fiat wrenching Danno. Will a thin wall socket fit? Last one I tried to get off, Ron ended up doing it for me, so there's a way without lifting the engine. I wouldn't use the oil pan to lift the engine if I were you.

So Cal Mark · Post by **So Cal Mark** » Sat Feb 25, 2006 9:38 pm

the manifolds can be really tough to remove with the head on the car, especially if it's mounted on studs rather than bolts. Expect to need a swivel socket, extension and a mirror

ventura ace · Post by **ventura ace** » Sat Feb 25, 2006 11:16 pm

You may want to remove the crankcase breather oil seperator housing to give yourself more room. Taking the starter out will give you even more room -- but that is not a fun job, and is probably not necessary.

Whether you take the starter out or not, you ought to disconnect the battery, or else you may end up with sparks flying if your tools short out the hot wire from the battery to the starter!!

alvon

Danno · Post by **Danno** » Sun Feb 26, 2006 4:57 pm

ventura ace wrote:You may want to remove the crankcase breather oil seperator housing to give yourself more room. Taking the starter out will give you even more room -- but that is not a fun job, and is probably not necessary.

Whether you take the starter out or not, you ought to disconnect the battery, or else you may end up with sparks flying if your tools short out the hot wire from the battery to the starter!!

alvon

Al, i took off the starter, and man did it help. I still have the one bottom bolt closest to the firewall to remove. Anyway, just thought I'd report that i did forget to disconnect the battery originally. BAD mistake. I'm sure you can guess the fuel and oil dripped around all in there. One little slip with the socket wrench and POP! and sparks! scared the bejeezez out of me, immediated thanked God that I still had my eyebrows and that there was no ignited fuel/oil/whatnot, and went back to D/C the battery. Just thought I'd throw that out there to any other newbies that think they can skip a 5 second step and leave that Bat connected!!!!!

Hjulen · Post by **Hjulen** » Sun Feb 26, 2006 5:54 pm

I once took the steering wheel off my car in order to clean it, as I removed the horn button I got a nice little shock that ran from my arm down my leg to where it was touching the car body.

It was "shocking"

to say the least, and certainly was enough to remind me to unplug the battery.

mdrburchette · Post by **mdrburchette** » Sun Feb 26, 2006 6:50 pm

another tip...make sure you reconnect the starter correctly. Great fireworks display if it's hooked backwards.

Danno · Post by **Danno** » Mon Feb 27, 2006 9:39 pm

SUCCESS!!!! (or should I say "suck-sess"). Let me just offer my 2cents to this manifold removal crap. It's not as stinking easy as it's made out to be. you CAN NOT remove the intake manifold by removing 2 screws on top and 4 scres on bottom. there are 5 screws on bottom. One is a shared screw with the rear timing belt cover.

Another cool piece of info. If you'd like to remove the manifold you need to deal with the tab from the rear timing belt cover because it will prevent you from pulling the manifold off. If you'd like to take that cover off, feel free. just keep in mind that you have to take out the tension bolt/spring thing. Not really something I wanted to do, so I did what any impulsive and impatient idiot would do. I got out my trusty dremel and hacked off that little tab. I don't see this ever being an issue except I might, at some time, develop an annoying rattle. Even with that little tab gone it was still pretty difficult to get that thing off because of the rear cover. I hope the 1800 doesn't have those clearance issues, cause I'm sure putting it on would be 10x harder.

So Cal Mark · Post by **So Cal Mark** » Mon Feb 27, 2006 9:55 pm

only the 2L used those rear timing covers, and they are sort of a pain to deal with. Almost everyone chucked those things the first time they replaced the timing belt. Are you also changing the exhaust? if not, you'll have to plug the egr hole in the cylinder head.

Danno · Post by **Danno** » Mon Feb 27, 2006 9:57 pm

so I can ditch the rear timing cover? How about the front cover?

I need to check my manual to see where this EGR valve is on the head, cause I don't see anything of the sort. BRB....
ok, Nevermind. Yeah, on the 79 and 80 carbed models that valve is right on the manifold, so I have already chucked it.

So Cal Mark · Post by **So Cal Mark** » Mon Feb 27, 2006 10:11 pm

you can leave the front cover off if you want, just have to be careful while working on and running the car at the same time.
The egr valve is on the intake, but the passage from the exhaust goes thru the front of the head. If you have the stock exhaust manifold and don't plug the hole, expect a huge exhaust leak

Danno · Post by **Danno** » Mon Feb 27, 2006 10:17 pm

So Cal Mark wrote:you can leave the front cover off if you want, just have to be careful while working on and running the car at the same time.
The egr valve is on the intake, but the passage from the exhaust goes thru the front of the head. If you have the stock exhaust manifold and don't plug the hole, expect a huge exhaust leak

You need to speak dumbese for me. This is new territory for me. Do you have a manual? I'm looking at page 10-128 and can't follow this stuff... I'll scan if it would help....

removing intake manifold.

removing intake manifold.

removing intake manifold

Re: removing intake manifold