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PostPosted: Mon May 05, 2008 7:07 pm 
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Joined: Wed Jul 18, 2007 7:19 pm
Posts: 22
Location: Bay Area
Someone was asking for pictures of the stock intake manifold. I just happened to have mine off for cleaning due to overheating, so I took a few. I was steered in this direction as a problem point from this post
viewtopic.php?p=82951#82951
I wont attempt to rewrite that article, but its a true fact, this manifold is integral in the cooling system. Mine was extremely clogged, no heater operation possible at all. The freeze plugs (20mm) were corroded as well, so I removed them. This allowed better cleaning inside with a pressure hose.
My heater bypass connections were shot too, but I managed to save the top one. The bottom was past salvage, so I fabbed up a stainless fitting using 3/4 pipe and a 1/2 pipe nipple. Then I silver soldered the joint. Tapping the bottom hole in the manifold is easy, just stop when you hit bottom. Checkout the little bypass hole in the flange. that was completely packed solid all the way into the jacket. The EGR valve plate on the bottom gets all clogged with carbon too. Clean her up, try her again! 8O

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