Intake Manifold Removal
Token Redneck
Joined: Jun 2007
Posts: 9,337
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From: Breckenridge, TX
There's a tab from the metal heater line that bolts to the the alternator mount. Did you take out that small bolt and bend the tab out of the way? Other than that... sticky gasket or crusty donut gasket. Heave on it a little bit.
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New User
Joined: Dec 2013
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I got that bolt also, my 2003 has a loop at the back of the intake manifold that sits right over HPOP cover. Not sure I can get off without removing the intake manifold. When I get home from work tonight im going to lean on it. Any hints on separating the back of the egr cooler from the up-pipe?
Logistics Pro
Joined: Dec 2004
Posts: 4,138
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From: South Weber, Utah
I got that bolt also, my 2003 has a loop at the back of the intake manifold that sits right over HPOP cover. Not sure I can get off without removing the intake manifold. When I get home from work tonight im going to lean on it. Any hints on separating the back of the egr cooler from the up-pipe?
Token Redneck
Joined: Jun 2007
Posts: 9,337
Likes: 346
From: Breckenridge, TX
There's a thin metal gasket, but it's not holding anything together. Push the v-clamp all the way back onto the up-pipe flange, and with just a little bit of pressure the EGR cooler and up-pipe will separate and the gasket will fall out.
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Token Redneck
Joined: Jun 2007
Posts: 9,337
Likes: 346
From: Breckenridge, TX
You said the hose on the EGR cooler was orange? You need the new blue hose or you're going to end up with a coolant leak in the valley. Part number should be: 4c4z-8592-AA. Or, part number 3c3z-9433-ab should get you the blue hose, plus new gaskets for each end of the EGR cooler, and a new donut for under the intake. I would think the EGR cooler gaskets are reuseable, but I don't know what your donut looks like.
Part number for intake gaskets is: 3c3z-9439-aa
Part number for intake gaskets is: 3c3z-9439-aa
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New User
Joined: Dec 2013
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Thanks for the picture and the part numbers, didnt know that the hose had changed its def an orange hose. Ill pick it up from the stealership tomorrow. Im really hoping it will come loose tonight. For Southern California its going to be a cold night (high 30's) and dont want to fight with it in the cold. Thanks again for everyones help, greatly appreciate it.
Token Redneck
Joined: Jun 2007
Posts: 9,337
Likes: 346
From: Breckenridge, TX
Grab that sucker by the alternator mount and pull straight up on it.
If you've removed the:
* two 15mm bolts to fan shroud
* one bolt to fuel line bracket
* one bolt to heater tube and bent tab
* 16 intake bolts (count them, twice. The very rear passenger side bolt is obscured by the downpipe. The rear drivers side has a very important FICM ground wire on it)
* loosened the 2 front EGR cooler bolts, and 1 rear mounting bolt
* EGR cooler v-clamp is positioned entirely on up-pipe or cooler
* EGR cooler orange hose is pushed back onto EGR cooler.
* intake horn (there's a threaded part that sticks through the fan shroud)
* oil and fuel filter upper housing
* injector harness
*MAP hose, dearation line, EGR valve and IAT2 wiring
...it SHOULD budge. And nothing should break because there's literally nothing else touching the intake except a potentially nasty set of gaskets under it, and if it is the EGR cooler stuck to the up-pipe it won't hold the front of the intake down and should lever apart.
If you've removed the:
* two 15mm bolts to fan shroud
* one bolt to fuel line bracket
* one bolt to heater tube and bent tab
* 16 intake bolts (count them, twice. The very rear passenger side bolt is obscured by the downpipe. The rear drivers side has a very important FICM ground wire on it)
* loosened the 2 front EGR cooler bolts, and 1 rear mounting bolt
* EGR cooler v-clamp is positioned entirely on up-pipe or cooler
* EGR cooler orange hose is pushed back onto EGR cooler.
* intake horn (there's a threaded part that sticks through the fan shroud)
* oil and fuel filter upper housing
* injector harness
*MAP hose, dearation line, EGR valve and IAT2 wiring
...it SHOULD budge. And nothing should break because there's literally nothing else touching the intake except a potentially nasty set of gaskets under it, and if it is the EGR cooler stuck to the up-pipe it won't hold the front of the intake down and should lever apart.
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New User
Joined: Dec 2013
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Bryan thanks for that picture and the instructions! Im going to print it out and take it with me, I do however think I got everything on the list and just need to pull that POS staright up. Thanks again for your time, prob not the best first big project on the X.
Token Redneck
Joined: Jun 2007
Posts: 9,337
Likes: 346
From: Breckenridge, TX
Good idea 
He does this one with a later model intake installed, OP, yours will be easier without the intake/EGR cooler in that way. When the pump comes out, make sure you get the branch tube o-ring and the yellow pump o-ring out, so you can replace them.
Start watching around 3:20 for pump cover and pump removal:
He does this one with a later model intake installed, OP, yours will be easier without the intake/EGR cooler in that way. When the pump comes out, make sure you get the branch tube o-ring and the yellow pump o-ring out, so you can replace them.
Start watching around 3:20 for pump cover and pump removal: