Time for a few upgrades

[rizzjc]

So, I've got this pile of stuff sitting in my garage, compliments of Mr. Smith:

Also have a replacement exhaust manifold to replace the leaking one on the passenger side. Wasn't quite ready for TMHs, but hopefully they will come down the road, when I decide on what to do with this engine long term.

Of course, as luck would have it, the first thing that needs to come off, the plate on top of the intake, won't budge. I have 3 T-20 torx bits. One is a craftsman hand tool, so I can't get enough torque on it with my bare hands. One started to twist when I put it in a socket wrench and started to torque on it, and the 3rd one won't fit right into the head, and was starting to strip the bolt out.

Just soaked it down with PB, which can hopefully get in there and get it loose. I freakin' hate torx!

 

[nssj2]

perdy. Ill be doing the same thing here shortly. actually, i think your old manifold is the doner . Curious to see how the spacer helps.

 

[rizzjc]

Well, in that case, I'll try to save it for you. That stinkin' emblem plate will NOT come off. CRAP! I might have to drill it out if a screw-out doesn't work.

 

[section525]

Parts look good! Hopefully those screws come out without turning this into a weekend-long project.

 

[rizzjc]

Too late. I'm sure this is just a sampling of what is to come.

This is what the screw that I have NOT stripped yet, did to my torx driver:

This is not gonna be fun, considering I have to save the intake. The plate isn't my biggest concern right now, but even if I drill out these screws, I still need to be able to get them out.

That's all for tonight. Off to a scuba class. I'll be looking for all of your brilliant ideas when I get home later.

 

[rizzjc]

Let me just add that the PLAN was to soak everything down on MONDAY with PB, so it was ready to go. Needless to say, that did not happen .... but this little plate was NOT what I thought I'd be worrying about.

 

[Turdle]

Oh, goodness.

Did you try some heat on it? Don't worry bout the top plate-you have an extra yes?

I think once the plate is off, you can get some pb blaster down the threads. I'll mess with getting the screws out-
Just get the head off those little things enough to get the top plate off.

 

[Rick]

Nice looking stuff I hate Torx too... I think half my bits have twist in them

 

[celly]

Well, in that case, I'll try to save it for you. That stinkin' emblem plate will NOT come off. CRAP! I might have to drill it out if a screw-out doesn't work.

That's what I had to do with mine once.

 

[nssj2]

nothing ever goes smooth. especially with tough torx bolts

 

[rizzjc]

Yeah, I'll try heat today, but the heads are probably too far gone, so I'll likely have to drill them out. Should save the top plate that way, but the top plate is the least of my worries. It's a rainy day, so hopefully after I get back home we can get these out. I'm gonna have a box of torx bits for Sears when I'm done.

 

[rizzjc]

Nevermind, I got it ....

The rest went a LOT better than that stupid plate. We got it all taken apart in less than 2 hours. Tomorrow we try to take care of the replacement exhaust manifold before we start putting anything back together. Hopefully those bolts come out OK.

I did found a small coolant leak, somewhere around the top of the water pump housing. Need to look at that a little closer. That kinda sucks, 'cause I'd really prefer not to get in that deep again. I won't be getting in there now, unless only to try to tighten a bolt or two, but it should be a little easier to see what's going on with everything else out of the way.

 

[Turdle]

^^^ha ha ha--what the heck hercules? I'll bet the language got a bit colorful up to that point-
I have a mental picture of you with a crowbar prying on that sucker.

 

[rizzjc]

I stayed pretty calm, but did say f* it, and went at it with a drill, hoping that what was left of the heads would pop eventually. It actually started to tear in the center, before the two corners snapped off. The rest of the bolts hardly took any work. Oh, and I will send back your rubber cap you left on the intake.

Not a lot of time to work on it today, but hoping to at least get the intake back in place while I've got a helper here. But I need to take care of that exhaust manifold first.

 

[rizzjc]

Anybody know what size the EGR hose fitting is? I need to cap it, since the new exhaust manifold has it, and the old one didn't since I have an internal EGR setup. I forgot to get one, and I don't have time to go get it, and install it, so I can get the intake back one while I still have help.

 

[wyochimneysweep]

i always use a impact driver on torx that are rusted in andussually have pretty good luck after some good blows with the hammer

 

[rizzjc]

Well, the exhaust manifold bolts came out easier than those torx. My buddy was here from up north, and could not believe they came out so easy. Unfortunately too much going on this weekend, so I've only got the exhaust manifold back on. Now it'll take me all week, or a really late night after work, to get the rest put back together.

 

[Turdle]

Joe-
I Think-almost certain the fitting on the manifold is an
-AN size-
5/8" is -AN10
3/4" is -AN12
1" is -AN 16

-1an size for every 16th inch is how you convert.

 

[rizzjc]

I measured the thread with the gizmo in my tap and die set, and it looks like the thread is a 16. I think I'll just take that EGR hose to Home Depot with me, or the machine shop, and find what screws into that, and then find a cap that fits.

 

[rizzjc]

I've gotta be the slowest person to ever work on their own car. Finally got back to this tonight. Found this the other day:

Looks like the front cover gasket is leaking. I replaced all of that last year. I'm sure I'm not fortunate enough for it to only be leaking OUT. Oil analysis should tell me how much, if any, coolant I'm getting in there. That was NOT a job I wanted to do again anytime soon. Worthless gaskets.

Other thing. Trying to replace the throttle cable bracket with this really neat powder coated one I picked up somewhere in Kansas. Anybody know how the cable comes off the throttle body? Looks like a ball and socket, but I can't find the clip.

It's at the bottom of the gray piece about mid-picture.