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Just got finished with a coolant flush and hose replacement and thought I'd post my two cents about this job. First - this was not fun. Pulling the intake is the only way this could have been done by me on this 1991 240. For anyone contemplating this job, here's what I learned. The intake has 8 nuts to be removed and all can be done with a combination of a 13mm socket, open end and box end wrenches. I could not see any way to get a torque wrench on the ones that needed regular wrenches so its a "feel" to snug it down at the end. The gasket goes on dry - clean the surfaces well with acetone and put a little anti-sieze on the nuts. The job can be done without opening fuel injector electrical connectors or fuel rail pressure boundary and only a few vacuum hoses need to be opened - the large one at the center of manifold and the flame trap tube. The support bracket at the bottom is easy enough from the topside. I must say that the designer of the heater hose locations was truly a sadistic bastard and I hope he is frozen in a fjord somewhere. I'm 6'-1" and 285lbs and my hands couldn't get in there to save my life. It was still tough on me with the intake pulled out of the way. The rest of the job - upper/lower hoses was a cinch and I gave her an oil change while up on the stands. I'm not too proud to say it took me 6 hours and I'm glad this one is behind me.
Regards,
Jeff - Baltimore, MD
1991 240 - 155,754 miles - clean as a whistle and runs like a top :-)
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