Intake manifold swap

[DocMayhem]

I am getting ready to do a bunch of maintenance on my Marauder, and wanted to know how much work the intake manifold is going to be and do I need to take the COT off? Can I leave the EGR tube on the EGR valve or do I need to separate them? I did a search and couldn't find the thread I was looking for that I remembered from a few years ago, were somebody with a high mileage DTR Marauder documented the whole thing, might have been fastblackmerc, but can't remember.
A few years ago I got a complete intake for cheap and cleaned it up and had it powder coated. Also have an alternator powder coated/rebuilt, new injectors, powder coated cam covers, probably do a water pump and oil filter adapter gasket too.
Any tips or tricks you guys have would be great. Also do I need to remove the windshield wiper motor/cowl?


Thanks in advance.

[Blackened300a]

I am getting ready to do a bunch of maintenance on my Marauder, and wanted to know how much work the intake manifold is going to be and do I need to take the COT off? Can I leave the EGR tube on the EGR valve or do I need to separate them? I did a search and couldn't find the thread I was looking for that I remembered from a few years ago, were somebody with a high mileage DTR Marauder documented the whole thing, might have been fastblackmerc, but can't remember.
A few years ago I got a complete intake for cheap and cleaned it up and had it powder coated. Also have an alternator powder coated/rebuilt, new injectors, powder coated cam covers, probably do a water pump and oil filter adapter gasket too.
Any tips or tricks you guys have would be great. Also do I need to remove the windshield wiper motor/cowl?


Thanks in advance.

I've removed my intake manifold several times, the cowl has to be removed to easily reach the back bolts, the crossover tube can remain in the head, just bend the mounting tabs up to make the manifold clear when removing, the EGR tube is to be loosened up in the back of the EGR sensor, and then remove the bolts that hold the EGR valve onto the intake lid.

The upper intake lid is be unbolted and carefully flip it over to the side with the coolant lines and throttle cable bracket still attached, then remove the bolts that hold the injector rail down, wiggle all the injectors out of the manifold, but keep them in the rail and flip it over to the side out of the way. Remove the alternator and all the bolts that hold the lower manifold down, on the very back of the lower manifold is a clip that holds a wire harness, be sure to remove that first, then you can lift the manifold straight up and out.

Ive had it out in about 20 minutes with no hassles. The gaskets can be re-used if they are not crushed or damaged. The hardest part of reinstalling the manifold is the EGR tube, I found that starting the EGR tube into the back of the valve then starting the bolts into the manifold was the easiest way to install it, other then that its pretty straight forward.