Intake Manifold and EGR Cleaning/Replacement - How hard is it really?

Gotcha haha sorry about that. Here ya go

I’ve done an initial pass on cleaning but will probably do some more for good measure.

 

Definitely some build up. Not completely blocked by any means though.

but some nice chunks and bits came out with a brass brush.

 

Need to do some more cleaning but they’re cleared out mostly

 

@Mendel Leisk having trouble getting the holes for the long stud to line up without forcing it down. I have the bottom stud installed to the exhaust pipe and nothing else is bolted down but I really have to force it down to line up and it’s difficult to thread in.

 

I got it but it was a tight fit

 

Ran into a snag with the Thermostat.
One of the studs has a bolt rusted to it. I got the entire stud out to try to save it and just get a new nut.


However I also broke off the 10mm bolt :/

Adding some pb blaster and letting it sit overnight and might try to torch it and use vice grips to get it out?

any tips?

 

Good day today overall.

9:30am-6:30pm with an hour for lunch.


Intake removed and initial clean
PCV valve replaced
oil catch can tubing from PCV routed
EGR system removed and replaced
Water pump removed
Thermostat removed
Spark plugs replaced

Tomorrow is:
tackling that broken bolt
thermostat and water pump install
Finish Oil catch can
Reinstall intake manifold and throttle body, etc.
refill coolant
Pray it starts up okay haha

any suggestions for that bolt are appreciated!! I’m really bummed about that, I could’ve had the water pump and thermostat done tonight but alas, no project ever goes 100% smoothly haha

 

I guess I should also ask, any idea what the size of that bolt is? I’m not finding much online other than part number 90105-A0079. Hmm

 

yeah, I was hoping to get a replacement from the hardware store to hopefully wrap up today, but given the difficulty it’s giving me getting it out, I may do it “right” and get new studs, nuts, and the bolt from the dealership. Hopefully they have them in stock to get this week, but we’ll see.

I have a family friend that might be able to help me get it out but it might end up getting towed to the shop if not. Ah the joys of working on cars, one rusted broken bolt away from a days or week long project lol.

Ugh haha

 

My thought process was just that given the rust and such on them if I was getting that one bolt I might as well get them all and not risk breaking another or in the future. But I suppose I could wire wheel them and clean them up a bit and reuse them.

the one bolt is about $2 according to online dealership sites.

No luck getting it out unfortunately. I don’t wanna muck it up even more than I have so I’m waiting until I get some experienced help haha. Got a family friend who might be able to make it out this evening and bail me out. He said if nothing else we can try and weld a nut to it and get it out that way.

 

Would the bolt be the same thread pitch as the studs?
I also am not sure the length of that bolt, since there’s not another one to compare it to. Just the two studs.

 

Side note: this is essentially what all 4 spark plugs looked like