How in the blue hell does this thing come off lads???

 

Scotty

This is taken from the faq section

done by andyduff

 

Im crap and cant get it to link

 

 

 

Basic removal procedure as follows:

 

Disconnect and remove the battery

Remove the inner and outer boost pipes on both sides

Remove Idle air feed tube

Remove the turbo outlet hoses - the outer black pipes coming from the tubs

Remove the balance bar

Disconnect all electrical connections (6 coilpacks, 6 injectors, fuel temp sender, idle valve, cold start valve and fast idle valve - last three on passenger side at back)

Remove 6 coilpacks

Undo 8 bolts holding the plenum down

Look to each side of the plenum, about half way back, there are 2 12mm bolts on each side - remove these.

Look under passenger TB, disconnect 2 rubber hoses (one going down to turbo coolant feed, the other goes to the front of the car)

Follow the pipework from the coolant hose and there will probably be a bracket to hold the pipe work - remove the 10mm bolt holding the pipes together.

You should now be able to lift the plenum slightly.

Lift it slightly, then undo the egr feed tubes on either side - 2x10mm bolts on underside.

Now work your way round under the plenum, and find any coolant hoses still holding it on - there will be one feeding the drivers side turbo and one at the rear drivers side from memory

PCV hoses should already have come off but remove if not.

 

That should be it. You should now be able to lift the upper intake straight off. Its not massively easy but just work your way round patiently and you'll do it

Guide with pics here

 

Steve :)

Oh a piece of p*ss then :headvswal

hi there scotty,

 

did mine was'nt to bad :wack:

 

biggest problem you will have is getting the 10mm bolts from the egr pipes luckily i had a set of ratchet spanners to do these :tongue:

 

now would be a good time to do a water bypass, or if not at least have a good look at the water pipes and think if they need changing before you refit the plenum :cool:

 

last thing you want to do is take it off again to fix a little leak :headvswal

dont forget your gaskets bud :bow:

 

plennum to intake manifold gasket

 

2 egr gaskets

 

1 gasket for the air idle valve at rear of plennum

 

o-rings for balance pipe,

 

p.s use some paint stripper on your balance pipe if it is black it will match your polished plenum then :)