Thread: Upper Intake Manifold Replacement [*]

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  1. #1 Upper Intake Manifold Replacement [*] 
    GTP Level Member 03GPScottyd's Avatar
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    (use for HV3 - High velocity intake insert)

    This HOW TO write-up on Installing an Intake Gasket has been added to the How To section and can be found HERE
    Last edited by 03GPScottyd; 01-04-2008 at 09:49 PM.
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    I live here. SyntheticShield's Avatar
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    man I sure am glad for all the how-to's. But is there any chance any of these have pictures with them? A lot of times a picture can make a world of difference when someone is following text and may not have the visual you would hope they have.
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    GTP Level Member 03GPScottyd's Avatar
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    Might take a while but it can be done. Just need to find somewhere other than Cardomain to post them.
    debadged, clear corners, 20% tint, tinted tails, vibrant performance tips, red painted calipers, Fig. grills, autometer guages, PFYC 3 pod A pillar, SLP CAI, 2.5" DP, SD Hood, SD front air damn, Gen I spoiler, 17X8 Borbet Type M rims, engine upgrades soon!
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    GTP Level Member J_Ferguson's Avatar
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    1998 GTP, U-Bend Delete,Hi-Flow Cat,No Res,SLP Headers,BRISK Plugs ,180 T-Stat, 3.4 pully
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    GTP Level Member TyroElite's Avatar
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    Or you can put them in your pictures here
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    pics really make the HOW TO section! very well written HOW TO!
    2001 GTP- PT76 turbo, Intense Drag cars old engine, Stage 4 Intense turbo cam,FMIC,150 wet,Double roller timing chain,Diamond forged coated pistons 8:0:1,Diamond piston rings,Cryoed L32 connecting rods,Cryoed crank,Clevite77 main bearings,Clevite77 cam bearings,Clevite77 L32 rod bearings,ARP Everything, Intense/meizere true billet Flexplate,Intense Wilson UIM/LIM,Intense oil pressure kit,Cometic,OE-R lifters,Cryoed L67 block,ATI turbo dampner,80# inject,Weldon 2035 fp,Aero Fuel Rails,AL cradle
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  7. #7 Re: Upper Intake Manifold Replacement [*] 
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    Do you have any experience with the lower intake manifold? I cannot get mine off, and do not know if there is a bolt hidden somewhere or if it is just really stuck on there.
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  8. #8 Re: Upper Intake Manifold Replacement [*] 
    The mod from over yonder TheOtherNick's Avatar
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    Could be stuck. Hit it with a rubber mallet. There should be 12bolts.
    01 gtp-big cam e85 dd 78dodge- guzzling fuel 05 cummins- rollin coal
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  9. #9 Re: Upper Intake Manifold Replacement [*] 
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    I worked on it in my father-in-law's shop and then went away for the weekend and he could not stand having it in his shop knowing we could not figure out how to get it off, so he worked on it some more. Turns out there were two more bolts from the inside that were covered by oil and once he got these off it came off no problem, so now I get to put it all back together without DexCool.
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  10. #10 Re: Upper Intake Manifold Replacement [*] 
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    i found a leak just behind the water pump on what i think is the uim. does anyone know if this the uim or the lim?
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  11. #11 Re: Upper Intake Manifold Replacement [*] 
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    What happened to the link? It went dead about a week ago.
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  12. #12 Re: Upper Intake Manifold Replacement [*] 
    SE Level Member GTPGP98's Avatar
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    Yep, the link isn't working for me either. I have a coolant leak that I believe is coming from the UIM. Was hoping to read through the HOW-TO before I tear into it.
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  13. #13 Re: Upper Intake Manifold Replacement [*] 
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    Link busted.
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  14. #14 Re: Upper Intake Manifold Replacement [*] 
    Turbo is the way to go. BillBoost37's Avatar
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    What do you guys need? I probably have most pics and can walk you through almost anything with my eyes closed, blindfolded, no car around and my ears covered.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  15. #15 Re: Upper Intake Manifold Replacement [*] 
    Turbo is the way to go. BillBoost37's Avatar
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    1. Disconnect negative battery cable
    2. If UIM only, no need to drain coolant. If doing LIM gaskets at same time (always suggested), drain the coolant.
    3. Unhook the electrical from the TB and remove TB cables from TB.
    4. Remove TB, looking at it from the front of the car, if there's a little metal bracket held on by an 8mm bolt, then remove the bolt and push the bracket toward the front of the car. Disconnect any vacuum lines to the TB gently. Remove the three 10mm nuts holding the TB to the UIM. Wiggle TB out from around the POS bracket.
    5. Remove 10mm nut and bolt holding EGR shield to motor.
    6. Using a 15mm untension the accessory belt.
    7. Remove alternator (13mm for battery cable), finger for the electrical connector, and depending on your year either 13mm or 15mm bolts.
    8. Disconnect map sensor (this is the sensor that is on the cap of the UIM next to the alternator)
    9. Using fingers or needle nosed pliers, remove fuel lines from fuel rail.
    10. Remove 4 10mm nuts holding the fuel rail to the LIM. Remove rail/injectors from motor.
    11. Gently remove brake booster vacuum line from UIM. It is held in with two clips. There may be a vacuum line on the piece.
    12. Remove a bunch of 8mm and a couple of 10mm bolts that hold the UIM to the LIM.

    Evap soleniods and or some misc vacuum lines may be in the way during the steps. Work with them,.

    Torque specs:
    Plastic UIM bolts: 89 inch lbs
    TB nuts: Little past snug, I want to think it's about 120 inch lbs
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  16. #16 Re: Upper Intake Manifold Replacement [*] 
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    BillBoost - Thanks. The son and I replaced the UIM gasket last night and those instructions are right on. Unfortunately, the vacuum lines at the rear were brittle and basically fell apart when we removed them so they were probably leaking to start with. Also had a fuel connection leaking so replaced the connections while we were in there. Heading to the store for some vacuum line this morning to finish it up. When we do this again to replace the UIM and fix the LIM with a Ken-Co Ind. plenum sleeve, it should go a lot smoother. Thanks again.

    Mike
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  17. #17 Re: Upper Intake Manifold Replacement [*] 
    Turbo is the way to go. BillBoost37's Avatar
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    Glad to hear it Mike. A couple of things you should know about that plastic upper.

    The only real issues with it are either a TB gasket leaking or the famous cracked UIM that spews gallons of coolant into the motor. The second part, can be permanently cured by plugging the coolant ports in the LIM. This can be found in a thread by me on "how to mod a lim". It also goes into opening up the side cover area to offset the blocked coolant. I've never heard of anyone having an iced up TB and needing the coolant going to it. Plus, if any one ever looks at how much coolant enters the TB..it appears to be very very little. I've run blocked coolant many years and it's never been an issue. By blocking that, you could reuse your existing UIM and never worry about it failing.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  18. #18 Re: Upper Intake Manifold Replacement [*] 
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    Ended up going to the Chevy dealer and picking up a new plenum. Not too expensive and if it gets my son through college (about 55,000 miles worth of travel over the next 3.5 years) I'll be happy. I will definitely keep the idea of blocking the coolant passages in mind though if we have more problems. We live in Texas and icing hasn't been a big problem!

    Mike
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