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Old 07-03-2021, 04:26 PM
Matt300ZXT Matt300ZXT is offline
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Join Date: Feb 2019
Posts: 111
The dreaded OM606 TD intake manifold removal

The actual question is at the end...

Is the bolt holding the manifold to the exhaust pipe literally the hardest part of the job of removing the intake so I can do the fuel lines, delivery valve crush washers/o rings and the glow plugs if I wanted? That was essentially a breeze.

Removing the wiper reservoir was easy, getting the intake manifold bolts out along with a couple vacuum lines and the accordion pipe bolt/bracket was easy, and getting to and removing the bolt underneath the car was easy. The hardest part was getting the splash shields out of the way that have been cobbled together after years of scraping on things, being removed for oil changes, bolts being lost, etc. If I had a longer extension and didn't have to put together every extension I could find, I could have gotten the bolt off even quicker. Mine has an allen head bolt in there though, so I'm guessing the original was lost long ago and replaced with a similar bolt.

Is the underneath bolt or the corrugated egr pipe supposed to be the devil to remove? Because once I had all the appropriate bolts out of the way, one good wiggle and my entire intake manifold popped right off. Now I just have to figure out how I'm going to attack these other parts.

Anywho, now that the manifold is out of the way, I could use a plan of attack to make sure I don't get in my own way and do something out of order and have to redo it:

I'm replacing all the fuel lines in the area, the delivery valve crush washers and o rings, and the o ring on the back of the fuel pump shutoff valve (which is where I think my leak and losing prime is coming from), the fuel pump shutoff valve, and there's probably another 1 or 2 o rings in there somewhere.
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