5.0 Intake.
Thread Starter
Joined: Nov 2009
Posts: 24
From: Texas
5.0 Intake.
This weekend, I'll be replacing the intake gaskets. What do I need for the job and what size sockets are they. Is it a pretty easy job for a beginner or not. I'll take any advice ya'll have. Thanks.
The Godfather
Joined: Sep 2005
Posts: 15,480
From: Temple, Texas
Upper and lower intake gaskets, or just upper.
In any since, it's very easy. The upper intake will take a beginner about 1 hour to pull off, although I can get it off in about 15 minutes. I forgot the socket size, but I believe all the bolts are 1/2". The lower will take about another 30-45 minutes, again, I could have it off in about 15, but I've done this a few times.
Process is simple:
For the upper intake only the fuel system does not need to be relieved. For the lower, you have to relieve the fuel system. On a 94/95 there is a button/sensor in the trunk just behind the mat on the drivers side, unplug it, then crank the motor over a few times, this will relieve the pressure. I believe the 87-93s have the same module, not sure where it's at exactly though, but I would assume in the trunk behind the mat. Easy to spot as it has a thumb sized red button that you push to reset everything, and yes you have to push it when you're done and ready to go.
*Undo the negative side of the battery and disconnect it.
*After that, undo the intake clamps and remove the intake.
*Unbolt the EGR from the throttle body assembly (you do not have to remove it from the headers although it will give you a little extra room.
* Unplug the wiring harness from the two throttle body sensors.
* Unbolt the upper intake, and remove it with the throttle body still on, you do not need to remove it. There are 3-4 (forgot the exact number) vacuum lines that connect to the intake and EGR system, take all those all.
*For the lower intake, drain the radiator system.
*Remove the upper radiator hose from the thermostat housing
*Unplug the thermostat sensor and temperature sensor.
*Remove the fuel lines (you'll need a special tool sold at autozone)
*Unbolt the fuel rails from the lower intake (2 on either side)
*Carefully pull up on the fuel rails at each injector, they will be firmly seated in place, and a few may fall apart at the top, but can easily be put back together.
*Unbolt the lower intake in reverse order it is to be installed (get a haynes manual), also barely break each bolt first, then come back and fully remove them, this will prevent warpage.
*Remove the PCV valve (now is a good time to replace the valve, grommet, and wire filter which is located inside the intake).
*Undo the two radiator hoses at the rear of the engine bay that connects to the heater tube (you can remove the heater tube or leave it on during uninstall, up to you)
*Remove the lower intake (you do not need to remove the distributer as there is just enough room for the lower intake to be pulled without doing so, you may have to remove the wires and distributer cap for extra room though.
Like I said, not hard at all, and I know it looks like a lot, but it's a quick job. For your first time it will probably take you about 3-4 hours, after that, you can do it in half the time if not less. Tools you'll need:
Flat had screw driver
Socket wrench
1/2" socket
Torque wrench
Fuel Line Removal Tool
1 or 2 other socket sizes may come up, but most are 1/2"
In any since, it's very easy. The upper intake will take a beginner about 1 hour to pull off, although I can get it off in about 15 minutes. I forgot the socket size, but I believe all the bolts are 1/2". The lower will take about another 30-45 minutes, again, I could have it off in about 15, but I've done this a few times.
Process is simple:
For the upper intake only the fuel system does not need to be relieved. For the lower, you have to relieve the fuel system. On a 94/95 there is a button/sensor in the trunk just behind the mat on the drivers side, unplug it, then crank the motor over a few times, this will relieve the pressure. I believe the 87-93s have the same module, not sure where it's at exactly though, but I would assume in the trunk behind the mat. Easy to spot as it has a thumb sized red button that you push to reset everything, and yes you have to push it when you're done and ready to go.
*Undo the negative side of the battery and disconnect it.
*After that, undo the intake clamps and remove the intake.
*Unbolt the EGR from the throttle body assembly (you do not have to remove it from the headers although it will give you a little extra room.
* Unplug the wiring harness from the two throttle body sensors.
* Unbolt the upper intake, and remove it with the throttle body still on, you do not need to remove it. There are 3-4 (forgot the exact number) vacuum lines that connect to the intake and EGR system, take all those all.
*For the lower intake, drain the radiator system.
*Remove the upper radiator hose from the thermostat housing
*Unplug the thermostat sensor and temperature sensor.
*Remove the fuel lines (you'll need a special tool sold at autozone)
*Unbolt the fuel rails from the lower intake (2 on either side)
*Carefully pull up on the fuel rails at each injector, they will be firmly seated in place, and a few may fall apart at the top, but can easily be put back together.
*Unbolt the lower intake in reverse order it is to be installed (get a haynes manual), also barely break each bolt first, then come back and fully remove them, this will prevent warpage.
*Remove the PCV valve (now is a good time to replace the valve, grommet, and wire filter which is located inside the intake).
*Undo the two radiator hoses at the rear of the engine bay that connects to the heater tube (you can remove the heater tube or leave it on during uninstall, up to you)
*Remove the lower intake (you do not need to remove the distributer as there is just enough room for the lower intake to be pulled without doing so, you may have to remove the wires and distributer cap for extra room though.
Like I said, not hard at all, and I know it looks like a lot, but it's a quick job. For your first time it will probably take you about 3-4 hours, after that, you can do it in half the time if not less. Tools you'll need:
Flat had screw driver
Socket wrench
1/2" socket
Torque wrench
Fuel Line Removal Tool
1 or 2 other socket sizes may come up, but most are 1/2"
The Godfather
Joined: Sep 2005
Posts: 15,480
From: Temple, Texas
Oh, to reseat the fuel injectors back into the fuel rails and the lower intake, take a little bit of oil and poor it into the oil cap from the oil container. Then use your finger, dab it in the oil and put a quick bead around each o ring. This will make them much easier to install and get seated properly.
Joined: May 2009
Posts: 8
From: south Carolina
After replacing everything I was told changing your oil is a good step as some of the coolant may have made it into the oil from removing the lower intake. I would also inspect and replace any of teh vacuum lines or rear hoses that connect to the intake while you have it all out IMO.
4th Gear Member
Joined: Oct 2007
Posts: 1,219
From: Phoenix, AZ
After replacing everything I was told changing your oil is a good step as some of the coolant may have made it into the oil from removing the lower intake. I would also inspect and replace any of teh vacuum lines or rear hoses that connect to the intake while you have it all out IMO.
D.R. THE PATHETIC DORK
Joined: Jun 2007
Posts: 30,871
From: West Virginia
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