Tools Needed:
Painters tape
Shop towels
3/8" Ratchet
3" Extension
6" Extension
8mm socket
10mm socket
13mm socket
needle nose pliers
fuel line dis-connect (or a couple picks)
Flat-head screwdriver
Dust remover can
Intake Cleaner
Drill/Dremel with grinding bits
1. Disconnect battery
2. Remove the intake tube connecting to the mass airflow and the throttle body
3. with painters tape cover the open side of the mass airflow and the throttle body to ensure dirt doesn't get inside the motor/air box
4. Unplug the connector on the passenger side of the throttle body (you will have to remove the gray clip first) and then remove the 4 10mm bolts
5. After removing the throttle body wipe it clean and for good measure put painters tape on the other side as well to keep crap from getting inside there while you're tearing the rest of the car down. make sure to also cover the opening to the intake manifold as well
6. To make it easier for removal/installation, unplug all the connectors on the passenger side wiring harness (fuel injectors/ac compressor/ground on cylinder head, etc etc) and pull it all the way back out of your way. the fuel injectors and fuel rail will be left on top of the intake for now
7. Do the same thing on the driver side as well, except you don't have to pull all the connectors off (still disconnect injectors) you can just pull it out of the way when installing/removing the intake manifold
8. disconnect the vacuum lines running to the front of the intake manifold
9. take the black cap off the fuel rail and with a pick push in the valve and release all fuel pressure (hold rag over the valve when doing so)
10. using your fuel line disconnect tool (or if you don't have one, picks) disconnect the fuel line where it connects to the fuel rail (get ready for fuel to pour out)
11. using the dust off can, spray all the dirt and dust you can away from the intake manifold area before you pull it off
12. with the 8mm socket you now remove the 5 bolts on each side that hold the intake down
13. double check to make sure you have removed everything from the intake manifold and all the wires are out of the way
14. remove the strut tower brace with a 13mm socket
15. lift the intake manifold off the motor slightly, you now will be able to access the vacuum lines on the rear of the intake manifold and disconnect them more easily.
16. wipe away all dirt from the intake ports on the cylinder heads and then cover with painters tape to ensure dirt doesn't get down in them
17. to remove the injectors and fuel rail from the manifold, simply twist the fuel injector back and fourth and it will "pop" out of the manifold (you will be leaving them connected to the fuel rail, leave the clips on the injectors)
18. wipe the injectors down and make sure the o-rings and nice and clean
19. with shop towels cram one in each intake runner to ensure a bunch of plastic residue won't end up inside the manifold
20. using a drill or dremel and grinding bits, grind away as much plastic material as you feel necessary, mainly concentrating on the parts where you can physically feel a lip. you don't need to grind more than 1" into the manifold on each runner to get it to how wide the rest of the runner is
21. after porting the manifold to your liking, remove the shop rags with needle nose pliers and remove as much plastic residue as possible
22. using the intake cleaner, clean the intake out as best as you possibly can. make sure to clean where the injectors plug back into the manifold as best you can
23. re lubricate the o-rings on the injectors, twist and push into the manifold and they will "pop" right back in place
24. go back and clean the valve covers, cylinders heads and all around where the intake manifold is going to set back onto the motor
25. (optional) go back and clean out with intake ports in the cylinder heads with a rag and intake cleaner
26. reassemble the way you took it apart! just make sure you get the vacuum lines back on the rear of the manifold and to the front, and plug all the connectors back in!
total time: approx 6-7+ hours taking your time, being a neat freak
results: car pulls alot stronger in the upper rpms!
EDIT: finally got to dyno my car, it is running really rich right now so there is still at least 10rwhp on the table! made for a nice gain across the whole board (ported intake manifold, ported throttle body, modified stock air intake, descreened maf, tune)
Painters tape
Shop towels
3/8" Ratchet
3" Extension
6" Extension
8mm socket
10mm socket
13mm socket
needle nose pliers
fuel line dis-connect (or a couple picks)
Flat-head screwdriver
Dust remover can
Intake Cleaner
Drill/Dremel with grinding bits
1. Disconnect battery
2. Remove the intake tube connecting to the mass airflow and the throttle body
3. with painters tape cover the open side of the mass airflow and the throttle body to ensure dirt doesn't get inside the motor/air box
4. Unplug the connector on the passenger side of the throttle body (you will have to remove the gray clip first) and then remove the 4 10mm bolts
5. After removing the throttle body wipe it clean and for good measure put painters tape on the other side as well to keep crap from getting inside there while you're tearing the rest of the car down. make sure to also cover the opening to the intake manifold as well
6. To make it easier for removal/installation, unplug all the connectors on the passenger side wiring harness (fuel injectors/ac compressor/ground on cylinder head, etc etc) and pull it all the way back out of your way. the fuel injectors and fuel rail will be left on top of the intake for now
7. Do the same thing on the driver side as well, except you don't have to pull all the connectors off (still disconnect injectors) you can just pull it out of the way when installing/removing the intake manifold
8. disconnect the vacuum lines running to the front of the intake manifold
9. take the black cap off the fuel rail and with a pick push in the valve and release all fuel pressure (hold rag over the valve when doing so)
10. using your fuel line disconnect tool (or if you don't have one, picks) disconnect the fuel line where it connects to the fuel rail (get ready for fuel to pour out)
11. using the dust off can, spray all the dirt and dust you can away from the intake manifold area before you pull it off
12. with the 8mm socket you now remove the 5 bolts on each side that hold the intake down
13. double check to make sure you have removed everything from the intake manifold and all the wires are out of the way
14. remove the strut tower brace with a 13mm socket
15. lift the intake manifold off the motor slightly, you now will be able to access the vacuum lines on the rear of the intake manifold and disconnect them more easily.
16. wipe away all dirt from the intake ports on the cylinder heads and then cover with painters tape to ensure dirt doesn't get down in them
17. to remove the injectors and fuel rail from the manifold, simply twist the fuel injector back and fourth and it will "pop" out of the manifold (you will be leaving them connected to the fuel rail, leave the clips on the injectors)
18. wipe the injectors down and make sure the o-rings and nice and clean
19. with shop towels cram one in each intake runner to ensure a bunch of plastic residue won't end up inside the manifold
20. using a drill or dremel and grinding bits, grind away as much plastic material as you feel necessary, mainly concentrating on the parts where you can physically feel a lip. you don't need to grind more than 1" into the manifold on each runner to get it to how wide the rest of the runner is
21. after porting the manifold to your liking, remove the shop rags with needle nose pliers and remove as much plastic residue as possible
22. using the intake cleaner, clean the intake out as best as you possibly can. make sure to clean where the injectors plug back into the manifold as best you can
23. re lubricate the o-rings on the injectors, twist and push into the manifold and they will "pop" right back in place
24. go back and clean the valve covers, cylinders heads and all around where the intake manifold is going to set back onto the motor
25. (optional) go back and clean out with intake ports in the cylinder heads with a rag and intake cleaner
26. reassemble the way you took it apart! just make sure you get the vacuum lines back on the rear of the manifold and to the front, and plug all the connectors back in!
total time: approx 6-7+ hours taking your time, being a neat freak
results: car pulls alot stronger in the upper rpms!
EDIT: finally got to dyno my car, it is running really rich right now so there is still at least 10rwhp on the table! made for a nice gain across the whole board (ported intake manifold, ported throttle body, modified stock air intake, descreened maf, tune)