Hi all,
I was quoted $250 today to remove the intake manifold and clean it of all the carbon. I called a machine shop that will soak it in their vat for $15. Naturally, I would like to remove the manifold myself and take it to the shop. Could someone please tell me the tools I need to do this job. Reaching all the bolts that hold the manifold on looks impossible with just a socket wrench.
Thanks,
Joe

I just did this a few months ago on my 92 300D 2.5. These directions should work for your car as well. Buy an allen wrench adapter set to go with ur set. I cannot remember what size they were, maybe an 8 or 10, you will also need a u-joint socket and extension to get to those hard to reach places. While your out shopping, you might want to buy a manifold gasket as well. It takes an hour to remove and another hour to reinstall on my car. You have to remove some linkage too, the just snap on and off. I hope this helps you some.

Johnson,
I removed my crossover pipe and cleaned it out, but the actual intake looked sort of intimidating. Did you notice a difference?When you removed the linkage, did you have to adjust anything when you put it all back together? Did uyou just pry apart the ball and socket sanp fittings? Did you have to remove any fuel lines? How many miles are on your car, any major repairs, any tuning tips? Sorry for all the questions, but it is once in a blue moon that I meet someone else that has a 300D 2.5. I have only ever seen two on the road, including mine.

Hello CJ,

I will try to answer all the questions I can. Yes they are very rare, I think I have only seen a couple on the road as well. I been looking for many many months for my car. Its black with dove gray interior, just the color I like.

When you remove the linkage, its a ball/socket type connection, they just twist off, remember which goes where though! No you do not need to make any adjustements to them when reinstalling them, they just snap on. Do not adjust the screw on the link otherwise it will through things off a little.

The repairs I have made? Umm I have replaced just about everything on my car, the last few months I have spent over $10,000 on it. Tranny, filters, light bulbs,tires, brakes, etc. Everything is replaced except the engine. The car is at 280,000 miles, I am hoping to get it to 312,000 so I can be a memeber of the 500,000km club. I usually do everything myself except tranny overhauls and other repairs that require special equipment and skills.

The manifold wasnt too hard to do, it does take time and patience, you need the tools I described in my previous post to do it. Just make sure you put the manifold against the block and then put the glow plug equipment on top of that, then screw it down. Otherwise if there is air getting into there, your car wont start or wont run right. Its hard to explain in words but when you take it apart you will see what I mean. You will want to take the manifold to a shop to soak it, cleaning the gunk out of it is the hardest part. Let me know if you have any questions or problems along the way and I will see if I can be of any assistance to you.

Did you have to remove the fuel lines? Do you remember step by step, what you had to remove?
Thanks!

Yes, I did have to remove the fuel lines. Remember where each one goes, if you have a digital camera, you can take a few snapshots before you start taking them apart, it will save you a lot of time trying to "put the puzzle back together" sort of speak.

Relax, on your car its automatic bleeding on the fuel system, so you dont have to manually bleed them. All I did was turn it to acc a couple times, and then try and start it.

I do not remember exactly step by step for the procedures. If I were you, I would defintly wait for warmer weather before working on it. Then open the hood to the highest position, (there are tabs on each side of the hood), and then just start with the small stuff and progress your way to the manifold. In order if I remeber correctly, cable linkages, crossover pipe, fuel lines, then the cruise control actuator, then your to the manifold. If you have done work on other parts of your car before, you shouldnt have any problems with this job. Feel free to contact me if you have any problems or questions before, after or while doing this procedure and I will see what I can do for you.

Chan,
What did you use to remove the fuel lines from the pump? Did you notice any sort of improvement with the cleaner intake?

I used a wrench to do the job. Its kind of tricky to get into some of those places. They make an injector line removal wrench that you can buy through Impco. I dont remember how much it costs, but I did the job without one so it is possible. You will need an open sided wrench, just becarful to not over tighten them or to strip them.

I did not notice any improvement. There was some oil/junk, inside there that I cleaned out, but I cannot notice any difference.