Help removing intake manifold

[ian_uk1975]

Ok, tried sticking a long ratchet extension bar into the thermostat housing in an effort to pry the intake off, only to have the thermostat housing crack under the strain!

Sliced through as much RTV at the rear of the manifold as I could... still no joy.

Have tried to lever the intake off with a screwdriver, but there's nowhere really to lever on, as the intake is pretty-much flush with the block and heads all the way around.

Tried sticking fingers into manifold through the thermostat housing hole and muscling the intake free... STILL no joy (and now my elbow's started hurting!)

Any other ideas chaps? I'm really stuck at the moment (and so is my bloody intake).

Cheers,
Ian.

[Nobby]

Originally Posted by ian_uk1975

Any other ideas chaps? I'm really stuck at the moment (and so is my bloody intake).

Cheers,
Ian.

Ian, do you have access to an engine hoist? I had to use mine when removing the intake manifold as it was stuck fast. I removed the carb, bolted on a lift plate and applied some lifting force with the crane (not a huge amount) then went round the seal with a stanley knife. It eventually just popped off. Easy.

It's also the only way I can remove the roll hoops. They really jam in place so I used nylon straps from the crane to pull them out. Better than a hernia!!

Good luck

[ian_uk1975]

Originally Posted by Nobby

Ian, do you have access to an engine hoist? I had to use mine when removing the intake manifold as it was stuck fast. I removed the carb, bolted on a lift plate and applied some lifting force with the crane (not a huge amount) then went round the seal with a stanley knife. It eventually just popped off. Easy.

It's also the only way I can remove the roll hoops. They really jam in place so I used nylon straps from the crane to pull them out. Better than a hernia!!

Good luck

Hi Nick,

Nope, no engine hoist

These are the sorts of things you just don't think to factor-in when doing something that should be a '5 minute job'. I wouldn't have expected to need an engine hoist to remove an intake! Oh well.

I'm going to try again tonight with a large screwdriver from the front of the intake.

Thanks,
Ian.

[JonnyT]

I have to say I winced when I heard about the levering on the thermostat housing!!

You can get long scalpel blades that are also very thin - might get a bit more of the jointing stuff cut between the mating faces - its amazing how many problems you can get from very small amounts of that stuff.

I've got an old, wide, blunted chisel that I use for breaking joints like that - it doesn't do as much damage to the mating faces as a screwdriver.

Rubber hammer might also help to break any carbonated stuff that is all adding to the sticking power.

[ian_uk1975]

Originally Posted by JonnyT

I have to say I winced when I heard about the levering on the thermostat housing!!

You can get long scalpel blades that are also very thin - might get a bit more of the jointing stuff cut between the mating faces - its amazing how many problems you can get from very small amounts of that stuff.

I've got an old, wide, blunted chisel that I use for breaking joints like that - it doesn't do as much damage to the mating faces as a screwdriver.

Rubber hammer might also help to break any carbonated stuff that is all adding to the sticking power.

I know, I know, but it was the only thing I could lever with!

I've got a chisel, but it's pretty new and very sharp. Might be worth gingerly trying to tap it between the intake and block though.

Will try rubber mallet, too.

[TINKA]

Have you got a good beam in your garage? Reason I ask is if you can make up a plate to go over where your carb goes on, with the edition of 2 holes in it towards the middle about 12mm. You could jack up your car then with the plate bolted on to the manifold tightly, take a rope and thread it through the 2 extra holes in the plate that you drilled and tie it securely. Then take the other end and tie it to the beam keeping the rope as tight as possibly. Once you are happy with it all let the car down BUT ONLY SLOWLY and once the rope is nice and tight stop lowering it and try to gently pry it off gently this should hopefully stop you marking any of the mating faces.HTH

[ian_uk1975]

Originally Posted by TINKA

Have you got a good beam in your garage? Reason I ask is if you can make up a plate to go over where your carb goes on, with the edition of 2 holes in it towards the middle about 12mm. You could jack up your car then with the plate bolted on to the manifold tightly, take a rope and thread it through the 2 extra holes in the plate that you drilled and tie it securely. Then take the other end and tie it to the beam keeping the rope as tight as possibly. Once you are happy with it all let the car down BUT ONLY SLOWLY and once the rope is nice and tight stop lowering it and try to gently pry it off gently this should hopefully stop you marking any of the mating faces.HTH

Rented Compton-style garage... pretty flimsy, so wouldn't trust the roof beams. Not a bad idea though. Will give it one last go with a selection of screwdrivers and hammers.

[maxGD059]

You beat me to it with that idea Tinks -I don't like the sound of any of the 'levering' plans. Also, I doubt any scalpel would do the job either

[keane]

Ian, just picked up on this thread, I know its a pain but be very careful resorting to too much force(dont ask how I know!!) if you have managed to cut or whatever the majority of sealing rtv etc it shouldn't need as much force as you are considering, just dont want to read in a few posts how the bolt holes cracked, have you any movement at all? if there is just rtv holding it then you should have some give albeit small if it is solid there may be something else, is there anyone close to you that can also take a look? just dont lose your rag or it will cost you. Dave

[TINKA]

Originally Posted by maxGD059

You beat me to it with that idea Tinks -I don't like the sound of any of the 'levering' plans. Also, I doubt any scalpel would do the job either

I wonder if it would be possible to get hold of 3 scaffolding poles and rig up a tripod