1. Disconnect negative battery terminal.
2. Remove intake hose between the mass air meter and throttle body.
3. Remove the distributor. (Use a marker pen to mark the position of the rotor on the lower cup of the distributor. Also note where the distributor base is at the engine block. Your distributor should have a hash mark on it for ease of reference. This will help reassembly)
Warning!Coolant may be hot, use caution when disconnecting hoses.
4. If your manifold has a decorative plate (5.0 H.O.) on top, you will need to remove the plate. Use a T-20 Torx to remove the screws then unclip the wiring harness locator from the manifold. (These screws are usually corroded and can be very challenging to remove. We use a small hammer to tap on the screw heads to help break them loose).
5. Disconnect the electrical, vacuum, coolant, and cable connections at the throttle body, EGR valve, fuel pressure regulator, IAC valve, and the upper intake manifold. (There are vacuum lines underneath and behind the upper manifold)
6. Using a 1/2" socket and extension remove the upper intake manifold bolts, then slide the manifold towards the front of the car and disconnect the vacuum lines that attach to the rear of the manifold and the PCV. Lift the upper manifold out of the car and set it aside. (Some models have a steel bracket that connects between the upper and lower manifolds in the rear. Remove and discard this bracket if applicable).
7. Unplug the wiring harness from the fuel injectors (Be sure to only pull on the plastic plugs, never pull by the wires), lower manifold connections, and oil pressure sending unit. Set the harness back and out of the way. (It is not necessary to remove the brown ground wire that bolts to the back of the driver side cylinder head).
8. Unplug the MAP sensor and remove the screws that hold its mounting bracket to the firewall. (The MAP sensor will be relocated in a later step).
9. Disconnect the water hoses that run to the heater core feed/return pipes and thermostat housing. Remove the small water hose that runs to the EGR spacer. (To avoid spilling coolant we use a wet/dry shop vacuum to suck the water out of the hoses).
10. Remove the sensors from the lower manifold and loosen the heater core feed/return pipe with a 1-1/8 open end wrench. (It’s best to do this while the manifold is still bolted to the engine)
Warning!Fuel System may be under pressure. Use extreme caution when releasing pressure. Extinguish all open flames and ignition sources when working with gasoline and vapors. Always wear protective eyewear
11. Carefully release any fuel system pressure by removing the cap on the fuel rail near the front end of the passenger side valve cover, behind the alternator and depressing the Schrader valve using a small screwdriver or pick. (Hold a rag over the valve while releasing the pressure to avoid fuel spray).
12. Use the fuel line disconnect tools to separate the fuel feed and return lines from the injector rails.
13. Unbolt and remove the lower manifold (The fuel rails will have excess fuel in them, use caution when removing to avoid spillage)
14. Unbolt and remove the fuel rails and injectors from the lower manifold. (Check each injector to make sure that both of the O-rings are in place. The O-rings have a tendency to get stuck in the fuel rails)
15. Separate the fuel pressure regulator from the stock fuel rail. (Skip this step if you are installing an aftermarket regulator)
16. Inspect the injector tips and O-rings for cracks or damage. If you have any questionable items, we recommend replacing them (available through auto parts stores).
17. To ensure proper sealing of your new intake, thoroughly scrape and clean the head surfaces, and engine block gasket areas. (Be sure to get any debris, oil, or coolant out of the ports in the heads, and the intake valley. A wet/dry shop vacuum works well for this)
18. Apply a 1/8" bead of RTV to the bottom cover plate mounting surface of the BBK lower manifold, install the bottom cover plate using 10-32 SS-BHCS’s and fold the anti-backout tabs over each bolt head.