Hi Jim,

There are so many things that make the intake R&R a bear...... In order of
pain:

1st- EGR tube disconnect AND reconnect. The nut is very tight and there is
very little play in the tube.
2nd- Bottom manifold 13mm nut. Can't even see it.
3rd- The lip on the forward end of the inner manifold that has to fit
behind the lower thermostat housing while re-attaching the EGR
tube and putting the manifold in the lower slot.
4th- The lower manifold bolts

I sure don't want to go through that again. If it weren't for the EGR tube
the job wouldn't have been nearly as bad or taken as long.

It took two of us to get the EGR tube back into the intake whilst wrestling
the manifold behind the thermostat housing then into the slot on the motor
mount.

Another option would have been to separate the two manifolds, but the thought
of getting all 6 tubes to seal properly was something I held as a last resort
only.

I'm glad our 98 doesn't have the EGR. If I have to do the intake at some
point in the future, at least that part of it won't be there to compound the
effort.

So.... the intake is back on (but everything is not re-connected yet), I
replaced the seals on the PCV box, replaced both knock sensors, cleaned the
EGR flow sensor, replaced the steering rack, inner and outer tie rods, checked
the lower control arm bushings for play, replaced the sway bar bushings and
re-torqued the sway bar end links. I also replaced the fuel injector
O-rings.

I should be able to finish hooking everything back up tonight or tomorrow,
I'll than bleed the power steering system and flush the brakes before letting
the car down off the jack stands..... Phew!!!

I ready to get this car back on the road. Tomorrow maybe.

DEWFPO
--
1998 S90 071,245 and 1995 964 154,100