- Spend a bit more time cleaning up the area, keeping debris from entering the coolant in the block (and the intake ports). Carefully clean the valley pan sealing surface - use a light solvent (eg., WD40) on a paper towel to wipe clean. I also ran a piece of 2,000-grit sandpaper over this surface as insurance. The surface should be nice and shiny when suitably clean.

- Dork Alert! Attach the new heat shield to the new valley pan PRIOR to installation of the pan: failure to do so will require removal of the pan, as the shield will not fit past the knock sensors if the valley pan is already installed. Take care when handling the new valley pan not to disturb the attached seal.

- Clean all twenty bolts. Apply a small drop of threadlok to each bolt, near the bottom.

- Install valley pan/heat shield - it only fits one way. Loosely install two bolts, one on each side, in the middle of the block. Loosely install two bolts, one on each end, to align pan. Once you are sure the pan is aligned, snug but do not tighten the first two bolts.

- Install the remaining sixteen bolts, working from the center outward, snugging each bolt, but do not tighten. When all twenty bolts are snug, tighten each, again working from the center outward.

- Clean and inspect the two water pipes. Pay particular attention to the ends where the o-ring seals will be positioned. Use very fine sandpaper (eg., 2,000 grit) to clean up the ends as necessary.

- Clean and inspect the manifold and engine block mating surfaces (A). Remove any remaining gasket material and ensure these surfaces are spotless - you really don’t want a leak here after everything is buttoned up.

- Carefully remove all four old o-rings - two from the manifold, and two from the water pump. Don’t nick the sealing surfaces.

- Carefully install four new o-rings - two in the water pump housing, and two in the water manifold. Make sure the o-rings are fully seated and not twisted. Apply a light coat of suitable lubricant (eg., silicon spray) to each o-ring.

- Carefully install the two water pipes into the pump housing, ensuring the o-ring is not damaged in the process. Push each pipe fully forward in the housing - this will give additional clearance in the following step.

- PITA Alert! In this step, the water manifold, six bolts, two gaskets, and two water pipes all get installed. I found the easiest way to do this as follows:

1. Insert one bolt into the driver’s side upper mounting hole of the manifold. Install one gasket onto this bolt - gasket only fits one way (hold manifold such that bolt doesn’t slide out, and gasket doesn’t fall off). Position manifold on engine block and start threads of first bolt - get it threaded maybe 3-4 turns. Be careful not to let the gasket fall off or the bolt slide out - if this happens you’ll spend ten minutes fishing it off the top of the header. You want as much play in the manifold as possible without risking pulling the bolt out of the hole.

2. Repeat this process with one bolt and remaining gasket on the passenger side. Note that you SHOULD be able to get the bolt threaded while still leaving enough slop in the manifold-to-block clearance to allow positioning of the water pipes in the manifold. Make sure you put the gasket on correctly. At this point your work should look as shown at B.

3. Now draw the manifold forward toward the block with one hand while guiding the tubes into their respective sockets with your other - when the pipes hit the o-rings they will hold themselves in place. Twist each pipe slightly to ensure proper seating - don’t pull them backward or they may back out of the water pump housing.

4. Making certain the gasket is correctly positioned, insert a second bolt into the manifold on the driver’s side and snug it up - do not tighten yet. Repeat this procedure for the passenger side.

5. Finally, insert the third bolt into the driver’s side of the manifold, snugging both it and the first bolt. Repeat for passenger side.

6. Finally, tighten all six water manifold bolts evenly. Once the manifold is tight, grasp and twist each pipe to center it between the water pump and manifold.

7. Once everything is happy, use a flashlight to check one last time that the gaskets are correctly aligned. Now stand up straight and stretch out your aching back muscles.

- Reinstall both water hoses, adjusting hose clamps so that the screws are accessible from above after everything is reinstalled (ie., plan for the worst - it IS possible to replace these hoses with the intake manifold installed).

- Locate the black vacuum pipe/hose assembly which came away from the car with the intake manifold. Follow the hose to where it connects to the lower right corner of the primary throttle body (A). Remove this hose (cut/remove factory crimp connector) and separate the vacuum plumbing from the manifold.

Secondary Throttle Body Disassembly

- Remove three T-30 TORX bolts hold secondary throttle body to main throttle body (B).

- Gently break seal and remove throttle body using a twisting motion

- Remove six T-30 TORX bolts (C) holding throttle body to intake manifold. PITA Alert! the lower three bolts (or more) will likely be stuck, and the heads will strip making traditional removal with the Torx tool impossible . If this occurs, use a small pair of vice grips to carefully break the bolt(s) loose, then remove with the Torx tool.

- Gently break seal and remove throttle body from manifold.

Rear Manifold Cover

- Remove vacuum hose (A) between fuel pipe and rear cover (leave attached to diaphragm on fuel pipe). Using a baggie and zip tie, seal off this hose (on fuel pipe side).

- Remove seven T-30 Torx bolts (B) from rear cover.

- Carefully break the seal between rear cover and manifold. Pull rear cover back and off of manifold.

Engine Vent Pipe

- The vent pipe runs up thru the center of the intake manifold, between the front and rear covers. It attaches to the rear cover via a rubber grommet, and clips into the front of the manifold. Gently press this retaining clip (A) inward toward the center of the pipe to release, and push the pipe out thru the back of the manifold. Note that this pipe is telescopic - it comprises two sections which join in the center and allow the pipe to expand slightly. This will become important during reassembly.

Miscellaneous

- Remove the front and rear seals from the Intake Manifold.

- Remove o-ring from front of primary throttle body.

- Remove the o-ring from the front of the vent pipe.

- Remove black vent pipe seal (black) from inside center of rear cover (A).

- Remove vent tube seal (blue) from lower driver’s side corner of rear cover (B).

- Remove brake booster grommet (red/orange) from rear cover (C).

This completes disassembly of the intake manifold. Clean all components thoroughly, noting the following:

- Use Simple Green, water/laundry detergent mixture, or a mild automotive parts cleaner to loosen grime from all components. Rinse with fresh water.

- Avoid getting water/cleaning solution in vent assembly on rear cover.

- Avoid getting injector nozzles in intake manifold ports wet (not a disaster if this occurs).

- Ensure all sealing surfaces are perfectly clean - especially the intake manifold runners and front/rear cover seal grooves.

- Dry all parts with forced air or lintless cloth/paper towels.

When all components are perfectly clean and dry, continue with reassembly.