should not take too long. you don't have to take valve cover off like I did. I was doing other things
one thing you absolutely need is swivel 1/4 adapter.
first take off fuel delivery line and injectors in one piece. I like to take things apart in big chunks. like in divide and conquer principle. obviously you need to take out intake hose, flush coolant and oil.
disconnect these heater hoses.
loosen power steering pump bolts. upper bolt is easy to access. lower 14mm bolt you either have to get underneath the car or guide your hand through route indicated by red arrow. you can see lower 14mm bolt if ps pulley's hole is in it's lowest position. but you cant get it unless you remove some mounts and lower the engine. use regular wrench. and use 12point side to loosen 14mm bolt.
then move ps pump out of the way. next unscrew 3 10mm pcv valve housing bolts. you don't need to disconnect ps return line. I did other shit so that's why it's disconnected.
then get underneath and you will see a bracket next to power steering pump. unscrew both 12 mm bolts.don't have pic of the bracket.
next unscrew these 2 12 mm bolts on driver side of intake.
now you will need to use the swivel adapter to unscrew the 10 bolts. some pic just to get an idea:
upper passanger side bolt
lower
I had to remove EGR valve because I did not have 1/4 wrench and mine did not fit. good idea to change egr valve gasket.
http://img442.imageshack.us/img442/6649/pic5uv5.jpg
and so on.
so one of the bolts will not come out because throttle body vacuum pipe will block it. I bent the pipe but you can unscrew indicated bolts and move the pipe out of the way.
remove EGR pipe going from exhaust to intake.
pry the pcv valve housing with screw driver. it's held by rtv sealant.
your intake is loose now.
also remove brake booster hose which goes from intake to fire panel. don't have the pic.
disconnect coolant temp sensor, egr temp sensor, throttle body sensor, basically all wires going into intake.
now you can pull it out in one piece.
if you want you can remove all electrical parts like IACV, throttle position sensor. throttle body and other parts and soak intake in degreaser. I found it's good idea to scrub as much as you can and then soak it in degreaser for couple of hours. then clean it. I used some degreaser from harbor freight. you can dilute it 1/20. so basically you can make 20gallons of degreaser for 10$. 1 gallon of that yellow degreaser is 10$ in harbor freight tools. some people use gunk.
you can replace heater hoses while you are there. size is 3/4inch. you will need 2 90degree angle heater 3/4 hoses.
I had to use 3 feet of 3/4 hose.
5 inches of 5/8 hose
5 feet of 7/9mm fuel line
5 feet of 4mm vacuum lines
1 foot of 5.6mm vacuum line
definetily replace the dipshit stock clamps with "ideal" brand clamps or something better. "ideal" brand clamps looked all round. and try to use fuel line clamps as much as you can. they are the best.
my intake and throttle body gaskets were blown big time. others were intact.
gaskets are:
intake plenum gasket.
intake manifold gasket
throttle body gasket
iacv gasket
pcv blow by gasket.
egr valve gaskets( don't know part numbers, I took my old ones to local dealer and bought there. 8$ for 2 of them.).
tricky part is to use pcv valve hose of exact length. I used a little longer. so then it was anoying to remove pcv valve and cut the hose, because the hose was bending and closing. for pcv valve you need pcv valve hose. get it an Merle's or Napa.
let me know if you need any other pic.
and big thanks to jserrano for his answers to my questions on his intake manifold gasket thread. I did not know the names of some gaskets.
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