Intake removal

[Blaise]

Hey guys:

Sorry for all of the questions. I have had this car for less than a month and am working on it daily trying to make it a solid runner. So, I am tackling many projects and sorting it out. Thank you for all the help.

I recently discovered a coolant leak that I can see pooling under the intake manifold. I blew it dry with compressed air and within a few hours a new pool of coolant appeared and was also seen under the car.

So, I am removing the intake parts and getting in there. All of these parts need cleaning anyway. I also look forward to cleaning and adjusting the throttle body.

Are there any parts that I should expect to replace along the way? Or items to check? I plan to replace the intake gaskets.

What is the typical sequencing of removal for these parts?

http://picasaweb.google.com/blaisedesco ... directlink

Blaise

[Blaise]

It appears that I must remove this part (EGR?) to remove the intake runners. But it is not obvious how it is done and there are plenty of signs of previous abuse in trying to remove or install it. I don't want to add to this. My manual does not mention it...removing it at least.

Any tips?

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/7B ... site"><img src="http://lh4.ggpht.com/_UZQuuBHQvx4/S_IGm ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... e">TIC-E12 intake removal adventure</a></td></tr></table>

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/kv ... site"><img src="http://lh5.ggpht.com/_UZQuuBHQvx4/S_IGn ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... e">TIC-E12 intake removal adventure</a></td></tr></table>

[Blaise]

I ended up removing everything...from it.

The bottom rigid line to it is stuck. I will leave it alone.

Cheers,

Blaise

[Blaise]

I decided to take the opportunity to install E21 intake runners. I have all my parts...E21 intake runners, new fuel line, loads of stainless german hose clamps, gaskets and some coolant hoses.

Ready to clean and tidy things up.

[Shoup]

Man that sucks you couldn't take the EGR valve off. I am going to try to remove mine when i swap my thermal reactors for normal manifolds (i have a '75). I disconnected the egr system and air pump after i passed my final emissions test here in CO, but havent removed the egr or thermals yet.

Side note: I re-tested after disconnecting the air pump and egr and got reduced emissions across the board without that crap... I'm glad my state doesn't require emissions tests for classic cars once they are registered. Because to pass emissions i would have to keep that stuff operational, thus increasing emissions. LOL!

[Blaise]

Shoup:

It is actually not that bad. There is a large collar nut at the bottom of it that is rather impossible to access without removing the intake runners, or at least loosening them. If you can loosen it, and remove the lower rigid line, then it should slide out of the intake.

I have been able to loosen the collar on mine, but it does not slide off. The problem is that a previous mechanic (idiot) really abused it.

Interesting that your car ran cleaner without the emissions system. Does it run better? Fuel consumption?

Hope that helps.

Blaise

[GripGreg]

Nice photo gallery. What I remember from this website is that you should start from the firewall at #6 with the re-installation of the runners. Because it's crowded. Then I think; awe shoot, just go to FAQ before you put stuff back together. SERIOUSLY!! Maybe someone else can help you.
Oh well,,,,Greg

[Peter Florance]

my factory manual shows a strange thin wall socket like a O2 sensor socket for EGR removal. I think for most mortals, the way you did it is best

[Shoup]

Blaise,
I think the reason i got lower emissions is that either the equipment was not functioning properly, or there were vacuum leaks that got solved while capping the lines for the airpump/egr.

I should say that i did do some other repairs between getting emissions when i bought it stock and then a month later. New e28 radiator and hoses, electric fan, new alternator and all belts, removed the AC condenser and compressor, cleaned some grounds, replaced a few wires, new air and fuel filters, removed airpump and capped egr lines.

The car ran much better after that. It would idle steady at 1000-950 instead of varying between 1100 and 1300. It starts faster; about a full second of cranking instead of 2 to 4 seconds like it used to. And all that got me a decent decrease in emissions, about 15% if i remember right.

My next project is routine brake work and also new brake lines because the 35 years have not been kind to the lines on the car right now.
Also in the works for this summer maybe: replacing thermal reactors with e28 3 to1 manifolds.

Did you get your intake cleaned and running yet? much improvement?

[Blaise]

I passed smog a few weeks ago....with flying colors. I expected to cut it close, but was pleasantly surprised.

As for my intake, I was chasing a coolant leak, but have found much that needed attention along the way. I hope to get it back on the road soon.

I am also tackling brakes and suspension next. I have some Bilstein HDs that I will install, stainless braided brake lines, caliper rebuild kits, and new pads.

The intake did clean up nice:

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/0c ... site"><img src="http://lh6.ggpht.com/_UZQuuBHQvx4/S_Y1S ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... e">TIC-E12 intake removal adventure</a></td></tr></table>

I will make some of these tonight:

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/lZ ... site"><img src="http://lh6.ggpht.com/_UZQuuBHQvx4/S_wRa ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... e">TIC-E12 intake removal adventure</a></td></tr></table>

BTW, I keep adding photos as I go.

[Adam Gravois]

Blaise, thanks for sharing your progress and especially this photo record of the process. It's so helpful for n00bs like myself to see the engine partially disassembled before we go mucking about in there, not that I'm planning an intake conversion anytime soon. Nice work on all that machining and cleaning. She's going to look a beaut.

[1st 5er]

Did you do away with the factory fuel rail?
Couldn't tell from the pics.

[Blaise]

The only things that I changed were the intake runners and some brackets to hold the items that used to hang off of the stock runners.

The fuel rail is stock and unchanged, just new hoses and clamps.

http://picasaweb.google.com/lh/photo/1f ... directlink

[Blaise]

This intake removal adventure has snowballed into much more work.

It started as me chasing a coolant leak under the intake...then finding out that my windshield leaked enough for my carpet padding to be soaked.

I have the engine back together and ready to roll. But my carpet was ripped out and I have the seats out as well. I have a few things to repair on the seats (will re-pad later). I look forward to driving it again.

Before:

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/9W ... site"><img src="http://lh4.ggpht.com/_UZQuuBHQvx4/TBqsu ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... ebsite">My E12 adventure</a></td></tr></table>

After:

<table><tr><td><a href="http://picasaweb.google.com/lh/photo/qa ... site"><img src="http://lh5.ggpht.com/_UZQuuBHQvx4/TBu8r ... r><td>From <a href="http://picasaweb.google.com/blaisedesco ... ebsite">My E12 adventure</a></td></tr></table>

If you are crazy enough to look through a million photos...here is a photo chronicle of some of this:

http://picasaweb.google.com/blaisedesco ... directlink

This link has the same photos as the one that I had originally posted in this thread, but has more recent stuff in it. I had a problem with my web album and lost my connection to the other link.

[1st 5er]

Went through them all.
Looks good.
How's she run?