Completely stumped on removing my intake manifold

[alex4]

'93 240SX KA24DEMy intake manifold gasket was leaking pretty bad. Looking into it further I found that the last owner had tried to seal it with rtv, but that didn't work. It would run rough and suck in condensation off the a/c compressor.I bought a new gasket, and have been removing the manifold, but I'm stuck. So far I removed: all 10 bolts/nuts holding it on fuel rail main top radiator hose it still has some little coolant hoses under it and some vacuum lines under it, but I think it is stuck on the EGR. I can't get the main egr pipe coming from the exhaust manifold off. The thing that attaches to the manifold is attached by two little phillips head bolts on the very back of the intake manifold. I have pryed with the crobar, and I got it to clear the collector studs, but I can't get it loose from whatever is holding it in the back. it's about half an inch away from the block but won't budge any further. i have some pics but they are pretty crappy so I won't post em just yet.HELP!!!

[krazydriver]

Well there's also 2 brackets holding the bottom of the manifold to the engine block. Think there's 5 bolts total between those 2 brackets.

The EGR piece is held on by 3 10mm bolts, just crack those out and leave the thing dangling for now. You've also got a bunch of vac lines that run into some stuff off the back of the engine block. 2 10mm bolts hold that mess on.That's all i can think of that you might have missed. Download the factory service manual, it shows everything in there.

In my car i had clearance issues removing it, I actually had to separate my manifold and remove the lower plenum before i could get the top runners out.

[alex4]

Alright, I thought it was stuck on the EGR, but I loosened it from the collector. I am pretty sure it is stuck on the Swirl Control Valve. Where the hell is that thing attached? It is right on the back of the block. There are two screws that are on the manifold but they are phillips head and I already stripped the phillips off of them trying to unscrew them. Can I detach the SCV from the car and leave it on the manifold as I pull it? Where is it attached?!Can I remove the studs on the block?
Modified by alex4 at 8:41 AM 7/9/2008

[TDS]

I dont think it would be stuck there. The SVC is on the intake mani and the sensor to that is behind the block. The only thing connecting them together should be a vac line. You should try to get the lower plenum off first like krazydriver said.

[alex4]

I already cleared the collector studs... it is stuck on something in the back near the firewall...

[krazydriver]

i guess i should have been more specific before... the vac lines go back to a mounting bracket stuck on the rear of the engine near the firewall. remove the 2 maybe 3 bolts that hold that and your going to have a MESS of vac lines hanging off the manifold, along with the bracket.

the solenoid for the SCV is also long and gets stuck on the EGR. you can easily unbolt the solenoid from the arm and slide everything out.... i kinda just hacksawed and started breaking stuff, because i was taking out the egr/scv/idle stuff anyways.

[480sx]

If you take out the studs that go into the head on either end of the intake manifold it makes the job 10000 times easier. Thats how the FSM says you should do it.

[liquid_cool]

i got down under the upper intake peice and unbolted the lower and forcfully removed it..he's rite thou on the studs..get rid of those and buy 2 new bolts the same length..will save ya the hassle later when reinstalling..if ya remove the lower half..it will get easyer..good luck.....

P.S. ..there are bolts hidden inbetween the upper intake area..you need a long exstention to get to em..wabble socket preferd..or thin wall socket..its tight.

[alex4]

I already cleared the collector studs... it is stuck on something in the back near the firewall...

[WhiteSandsSE]

Water hose in the rear is hard to see, and a pita to remove