I am replacing the coolant temperature sensor on my 90 - 240. Most of the FAQ info said to take off intake manifold to get to it. What is the minimum I can take off to get the intake manifold off and replace the sensor? As always, any information will be appreciated and helpful.

Thanks again,

Don
dazsa

Ringlee's advice is great. The only thing is, you can leave the fuel rail alone. Just move the manifold far enough back so you can get in there. The manifold takes about 10min to remove once you've done it a few times. Leave the throttle body on as well. Just pull off the little PCV hose from the flame trap housing, and perhaps the ones at the throttle body (depending on how far they'll flex).

Also, good time to check the oil trap and flame trap if you're so inclined... heater hoses are easy too. This sounds like a huge job but in reality it is nothing at all.

Careful of the throttle cable and transmission shift control cable from the throttle spool. You don't want to break them. Basically if you use care you'll come out fine.
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Chris Herbst, in Wisconsin.

I actually did mine without removing the manifold. You will need a crow-foot wrench or a stubby open-end wrench to get up in there. Count on some skinned knuckles. I recall smashing the plastic connector to get it off as well. If the sensor is stuck, then just remove the manifold by:
-disconnecting the air hose, vacuum hoses, and electricals to the throttle body
-disconnect the three cables to the throttle pulley. REMEMBER how these go on so you can replace them (a digital or Polaroid photo helps)
-remove the fuel rail in one piece
-remove the manifold

The Mechanix gloves that you can get from iPd or Autozone for ~$20 are worth their weight in gol when it comes to saving those "skinned knuckles". Check them out!

Ian

You do not need to remove the manifold, or at least I never did. A U-joint socket setup will help, but I did it with just an extention and the proper sized socket. You may need to remove some intake hoses or even the throttle body, but that should do it.

dick