89-91 Non Turbo Intake on an 86-88 Block

Disassembly    Modifications    Re-Assembly    Tuning    Counter-Points

DISASSEMBLY STEPS:  (This is the easy part....)

I recommend that you keep a notebook close by before you start unbolting things.   I wrote down everything in the order it was removed in order to ensure that I could put everything back on.  ALSO!  Before you do anything, STUDY the vacuum routing of every hose on the entire manifold!  You should understand where every vacuum line goes before you start popping them off.  If you don't have a factory manual or Haynes manual handy, you can check out Travis Shrey's web page.  Travis took the time to color the factory vacuum diagram and its very easy to follow!  (Thanks Travis!)  Do not start tearing into things until your absolutely sure your ready!

Once you know where everything goes, you can start "ripping" into things...  The upper intake comes off like this:

1)    Disconnect the battery

2)    Remove the Air-Funnel (Black plastic intake) (PIC)

3)    Remove the Alternator

4)    Unplug the TPS (PIC)

5)    Remove the Accelerator and Cruise cables

6)    Disconnect the "oil metering pump rod"

7)    Disconnect the Water hoses - there are 2: One at the BAC valve and at the back of the intake  (PIC)

8)    Disconnect the BAC connector

9)    Disconnect the fuel hoses from the upper fuel rail.  

10)  Disconnect the Air Intake sensor located above the oil filter

11)  Disconnect the upper fuel injector electrical connectors

12)  Disconnect 11 vacuum hoses

13)  Remove the 4 bolts that hold the dynamic chamber up

14)  Remove the 4 nuts and 1 bolt that holds the upper intake to the lower intake.    

15)  The upper intake, dynamic chamber, and throttle body can now be removed.  (PIC)

16)  At this point, Remove the Air-Pump.

The next task I performed was to remove and block the EGR valve.

1)    Locate the EGR valve on the top of the engine. (PIC)

2)    Remove the nut and bolt that holds it on and remove the EGR valve.

3)    Locate a piece of 1/4" aluminum plate that is at least 2" wide.  (The valve is exactly 2" wide) (PIC)

4)    Cut, shape, and drill your new block off plate.  (PIC) (PIC2)

5)    Install the new block off plate.  Be sure to use some high temp gasket material.  (PIC)

Next step is to remove the lower intake manifold

1)    Remove the ACV (2 bolts and 1 nut) (PIC)

2)    Remove the 6-port actuators

3)    Disconnect the two oil injectors from the manifold.  BE CAREFUL not to break the plastic lines.

       You can see the oil injector lines in this (PIC)

4)    Remove the split air hose that leads to the catalytic converters

5)    Remove the lower intake.  There are 6 nuts that hold the lower intake on.

You can see in this picture that my oil injectors are working VERY well!  (PIC) 

You'll now have access to the 6-port sleeves.  They should slide right out, but you might need to grab them with a pair of pliers.  (PIC) (PIC) Make a mental note of the orientation of the 6-port actuators.  The little shaft inside the sleeve should point at 5 and 11 o'clock.

Disassembly    Modifications    Re-Assembly    Tuning    Counter-Points