Inlet manifold removal

Did my manifold over the weekend. It is a bit of a pig of a job but do-able DIY if you have patience and some tools.

Key bits of advice from me:
- The bolt behind the fuel pump can be accessed with a cut down M10 Spline. I cut to 50mm and then used a 10mm spanner on the bit. Just need slacking off.

- The temperature sensor in the head needed to come out for me as it just wouldn’t squeeze past.

- Job is 100x easier if you can remove the rad pack. I took mine off the mounts and rested on the crash bar but made visibility quite poor for the lower bolts. Do-able this way but if you have no AC or the ability to remove and fill gas just take the lot out completely.

- Don’t bother trying to take any short cuts, just remove everything and keep the bolts in the brackets etc as you remove them. Makes the job longer but will save time in the long run.

Failing all that, Laser Tools do the special tool for removing the bolt behind the pump as part number 8822.

Enjoy!

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I’m looking to change my intake manifold, it’s got 153k on the clock and not sure if it’s been changed before. Is it just the intake manifold kit I need to buy or are there any hoses or additional gaskets I need replace on anything whilst there?
Thanks.
 
EGR Pipe Gaskets.

I’d also consider the glow plugs at 150k if you’re in there.. they aren’t cheap though.
 
EGR Pipe Gaskets.

I’d also consider the glow plugs at 150k if you’re in there.. they aren’t cheap though.
Is see three of the glow plugs are relatively cheap, the fourth with the pressure sensor is the expensive one. Thanks for your response
 
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