Ok, finally fucking done. I must say, I will not be doing anything to my car for a very long time. I am sore, tired, I got really desperate for a couple moments, and I really, really need a shower.
I am almost at 122k MILES, none of that pussy KM shit.
The manifold removal is actually fairly simple. How do I know? Because like many of you before me that have done this, I did it twice. Fuck! Marting (mec) and I had the whole thing back on, aside from the up pipe, and I look down and notice that one of the tumble flap fucks was sitting there. I had put the three back when we were finished with them, and forgot to replace the last one when we were done with it. I was willing to say fuck it and see how it ran, but luckily Martin talked me down and was willing to pull it all out again with me.Sooo, the second time around, it took us about an hour to remove and replace. Could have been less if we would have just slowed down and thought about it better, but we were trying to take shortcuts. That was where the desperation kicked in and I felt the fear.
So, a quick before and after. The flaps were so dirty you could see wind marks cut through the carbon and it was growing over the edge, like a windy desert.
So, here's what I did. Three cylinders were completely closed, so I used BG ISC cleaner (per Bman005's suggestion) and filled the cylinders up to the top and soaked them overnight. I used a turkey baster to suck out about half of the juice, then used a combination of a flathead and a paint can opener (the curved tip works pretty well to get places the flathead can't) to scrape the goo off everything. It literally falls right off. Then I tried to suck the rest of the chunky juice out with the turkey baster.
PROBLEM: The turkey baster was plastic, and the BG stuff started melting it by the time I got to the 3rd cylinder, it was toast. It was an awesome method, but you will need a glass turkey baster, or maybe one of those rubber baby snot sucker bulb thingies would work too.
Then it was just a matter of cleaning up the residue with a flathead and a couple cloth towels. After the valves were fairly clean, I filled it with fresh BG and soaked it again, until I cam e back around to it. I also used my air compressor to blow anything out of the cylinder that I could, blocking the juice with a towel. This got a few hard to reach chunks out as well.
After the first 3 were done, I used a 19 mm socket and a ratchet to turn the crank and close the first cylinder from underneath the car. There is a rediculously poorly placed electrical connection right in the way that is held there with a plastic barbed compression tab. Martin was able to get a C clamp around the wiring and pull it out of the way. There is not room there for a human hand. Worked great, and just a few turns clockwise (with car in neutral) and the 1st cylinder was closed.
Literally the only things you need to do this job are
A T30 socket bit
A 10"-12" extension
A 4" extension
A 17mm wrench
An adjustable wrench
A phillips screwdriver
Pliers
2 cans of ISC cleaner (I didn't use all of it, but definitely more than 1 can)
4 O rings to replace on the injectors
A 10 mm socket
The triple square bit (if you have abanjo bolt style HPFP)
An M10 socket (a 4" long one is recommended, this is what I had. You might be able to use a normal one with an extension)
You do not need to remove the HPFP, just the fuel lines from it.
I don't believe that you need to disconnect the coolant tube, but it definitely helps. Not too much coolant comes out anyway.
Pretty sure that was it.
edit: forgot to add I used a wire brush to get those flaps squeaky clean.
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Originally Posted by DRAKLORE
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