Intake Cover Removal [Archive] - GRRRR8.net

GRRRR8

08-10-2008, 03:34 PM

Loosen the outer bolts working your way to the center. Only remove the 4 long bolts in rear with the black brackets (8mm socket). Then take off the 4 10mm studs that hold fuel rail. Disconnect the black plastic tube that goes to drivers rear valve cover. Remove injector harness push in black hold downs from fuel rail. I did not unplug any electrical connections. Carefully take a long screwdriver and lightly pry up at the base of front injectors on both sides, then do the same at the rear. Lift fuel rail enough to slide cover out the front. Now take pcv tube to drivers side valve cover and carefully slide under fuel rail and carefully install fuel rail making sure all injectors are in their holes before pressing down. The pcv hose now is very neat. Torque all bolts 1st step 44in lb from center out and repeat 2nd step at 89in lb.

http://i295.photobucket.com/albums/mm132/charlesvanwormer/Upsized%20Photos/DSC03716.jpg

http://i295.photobucket.com/albums/mm132/charlesvanwormer/Upsized%20Photos/DSC03714.jpg

G8V8

08-12-2008, 05:06 PM

Charlie,
In my Grand Prix days I had a 2004 GTP Comp G. There were some problems when guys removed the injectors. If they did not replace the o-rings they would eventually leak and there were a number of fires.

We alsways replaced the o-rings, did any injector work only on cold motors and relieved the pressure before removing injectors.

Any concerns about the G8 along thse lines?

I assume you would want to do the intake cover removal on a cold engine anyway because of re-torquing the intake manifold, right?

GRRRR8

08-12-2008, 05:11 PM

The problem on the 3800 supercharged was techs would not get the injetors line up and nick the orings on the aluminum intake. We have a plastic intake. If you take your time, no issues at all. 0. Nada.

G8V8

08-12-2008, 05:26 PM

Thanks.

cold engine is better for re-torquing, right?

GRRRR8

08-12-2008, 05:29 PM

You are correct. Just so most of you know a lot of common sense goes a long way with DIY projects. If it does seem right, its not. If it feels like its gonna break, it will and so on. If we get to these points in a project, put the wrench down and open the lap top and ask me.

-Ray-

08-12-2008, 05:46 PM

I had the forum open when I did mine at the muffler shop in town. My injectors pressed back in with just a little effort.

GRRRR8

08-12-2008, 05:50 PM

<div>
(G8 Ray @ Aug. 12 2008,9:46)</div><div id="QUOTEHEAD">QUOTE</div><div id="QUOTE">I had the forum open when I did mine at the muffler shop in town. My injectors pressed back in with just a little effort.</div>
Did you find my post was detailed enough to DIY or was there some gray areas?

GeorgeInNePa

08-12-2008, 06:29 PM

I did not need to remove the harness clips. In fact the first few times I read that, I couldn't figure out what you were talking about.

I was sliding the cover out and looked at the harness and said, "that's what he meant!".

lol

GRRRR8

08-12-2008, 06:31 PM

My harness was real tight. I just did it to make sure. I would say if the rail gives you ample space to slide it out, skip it. If not unclip them.

EcoBrick Bob

08-12-2008, 06:42 PM

My torque wrench was in foot lbs. not INCH lbs. Works out to about 7 1/2 Foot Lbs. (NOT VERY TIGHT!) Glad I read Charlie's detailed post on how to remove and checked the conversion factor on the internet (divide by 12).

EAZY as PIE!

RRM

- Not ready for prime time mechanix!-

-Ray-

08-13-2008, 05:24 PM

I had the forum open when I did mine at the muffler shop in town. My injectors pressed back in with just a little effort.

Grrrr8
Did you find my post was detailed enough to DIY or was there some gray areas?

Lets say you're not a technical writer, and I'm not completley stoopid. I was able to figure it out.

GRRRR8

08-13-2008, 05:27 PM

LOL! That was my goal. Put you in the right direction and let you run with it.

G8V8

08-16-2008, 05:56 AM

I removed mine this morning. My first Charlie Mod!! Took less than 30 min. Piece of cake. Thanks Charlie.

GRRRR8

08-16-2008, 06:20 AM

Someone was up and at it this morning! Congrats on the 1st GRRRR8 mod. Now take a drink and finish the back up camera!

G8V8

08-16-2008, 07:19 PM

Yes Sir! Will do.

It's A G8!

09-20-2008, 04:11 PM

I think for the 09' the cover if different.I was under the hood today and just out of curiosity I pull the cover and it came right off. It was not bolted to anything. Just thought I would let you guys know.

GRRRR8

09-20-2008, 04:14 PM

Thats the top silver cover. The black one beneath that is what we remove.

It's A G8!

09-20-2008, 04:23 PM

I didnt see a black one under there.

GRRRR8

09-20-2008, 04:27 PM

It looks like its the intake that you are seeing, but that actually is the cover.

It's A G8!

09-20-2008, 04:33 PM

Ok I will check it out.

GeorgeInNePa

09-20-2008, 04:41 PM

I didnt see a black one under there.

http://img.photobucket.com/albums/v320/GeorgeInNePa/G8/0706081816a.jpg

whlspin4ever

09-24-2008, 09:52 AM

Quick question:
(Sorry, new to the site...)Does anyone know why GM put the intake cover on the engine at all? NVH? The engine already came with an engine cover, why the need for a second intake cover?

I like the idea of taking the cover off.....would make cooling the intake on Track days easier!! :D

Thks
Dave

GRRRR8

09-24-2008, 10:00 AM

NVH is correct. It is a must remove so you can ice/cool down in between passes and it helps on normal street driving if you moodded the hood also.

whlspin4ever

09-24-2008, 10:07 AM

Did the hood vents! I'll be taking that cover off tonight, hopefully....

Thanks for the detailed instructions! Did you have any gas leakage or pressure when you popped the fuel rail off?

GRRRR8

09-24-2008, 10:08 AM

No sir. Taking your time maybe 30-45 min.

wreckwriter

09-24-2008, 10:08 AM

Did the hood vents! I'll be taking that cover off tonight, hopefully....

Thanks for the detailed instructions! Did you have any gas leakage or pressure when you popped the fuel rail off?

You don't disconnect the rails, just raise them up a bit, no leakage.

whlspin4ever

09-24-2008, 10:16 AM

OK, Thanks for the info!

:offtopic: GRRRR8 - I'm trying to find the thread and PICS for the lower panel mod. Can't seem to find it. Can you point me in the right direction? :cheers:

whlspin4ever

09-24-2008, 10:22 AM

OK, forget my last question. I found the thread...duh. I was looking in the DIY section.

I'm a :loser:

Tate

10-08-2008, 08:32 AM

So I did this on Saturday after I installed my Rotofab Intake. Took all of 15 minutes, and that is because I didn't have a deep well socket that small for the rails bolts. I went to the track on Friday night and was throwing ice on top of the damn thing and wondering why it wasn't cooling down. After seeing the chunk of foam/rubber under the cover it made much sense why it didn't cool. Easy free mod and very worth doing for anyone.
Tate

BlueJacket

10-08-2008, 09:39 AM

Very easy mod to do. Just don't be like me and break one of the fuel rain studs off in the intake. That was a fun repair. :punch:

GRRRR8

10-09-2008, 07:23 AM

Very easy mod to do. Just don't be like me and break one of the fuel rain studs off in the intake. That was a fun repair. :punch:

Did you get it all done and fixed?

BlueJacket

10-09-2008, 08:19 AM

Did you get it all done and fixed?

Yeah got everything fixed. The stud broke off at an angle, I tried to use an easy out but I could not get it centered and there was no way to grind down the stud since it broke off down in the hole. I ended up drilling out the stud, taping the hole and putting in a helicoil. All is good now and you can not even see that I messed it up. lol

GRRRR8

10-09-2008, 08:20 AM

Lesson learned. Glad it all worked out for you.

BlueJacket

10-09-2008, 08:30 AM

Lesson learned. Glad it all worked out for you.

Sure was, I like when the lesson is a cheap one. I could have done somthing real stupid and needed a new fuel rail or intake.

At least now I know how to fix a broken bolt if it every happens again. And it gave me a reason to buy some more tools.

GRRRR8

10-09-2008, 08:32 AM

Its like it was destiny! More tools are always a good thing. As soon as I clean up my tool box I will take pics for everyone. Almost 250k in tools. I can break it, fix it and redesign it! LOL

jnak

10-09-2008, 08:32 AM

New tools FTW!

BlueJacket

10-09-2008, 08:44 AM

Its like it was destiny! More tools are always a good thing. As soon as I clean up my tool box I will take pics for everyone. Almost 250k in tools. I can break it, fix it and redesign it! LOL

I am sure that pic will make me fill good about my 260 piece socket set. :boxing:

GRRRR8

10-09-2008, 08:48 AM

LMAO!!!! It will help you go DEEP in debt like I did early on in my career. I had a 30k credit limit with Sanp-On. IDIOT! I owe about 12k and its all paid off. In 16 years I paid for a nice house I cant sleep in, but I sure can fix some shit! lol

BlueJacket

10-09-2008, 08:52 AM

lol I now have about everything that a normal person would ever need to do most things that can be done in someones garage. I just need a better torque wrench. Any suggestions?

Chewy

10-09-2008, 08:55 AM

lol I now have about everything that a normal person would ever need to do most things that can be done in someones garage. I just need a better torque wrench. Any suggestions?

Check Sears out.

I have cheap a$$ Harbor Freight ones which work but it would probably scare me to know how far off it is...:blink:

GRRRR8

10-09-2008, 10:20 AM

lol I now have about everything that a normal person would ever need to do most things that can be done in someones garage. I just need a better torque wrench. Any suggestions?

For most of your needs get an inch lb 1/4 or 3/8 drive and a 1/2 inch drive that goes from 20-250 ft lbs and you are good to go. The cheaper they are the more inaccurate they are if dropped or used as a hammer! lol

BlueJacket

10-09-2008, 10:32 AM

GRRRR8

10-09-2008, 10:40 AM

Unless they are hi-end, no. Just the ole click type will do.

BlueJacket

10-09-2008, 10:41 AM

Thanks

Greg@PacePerformance

10-09-2008, 10:44 AM

^^^^^^
My dad has one like that. I have a Sears click type and it seems to work good. I also bought one of these.
http://www.techsourceky.net/cbcb2640.JPG

It does TTY bolts and standard bolts. ;)

BlueJacket

10-09-2008, 10:56 AM

Pic not working

Chewy

10-09-2008, 11:54 AM

Pic not working

Working here!

BlueJacket

10-09-2008, 12:17 PM

Must be my work network. I will check back when I get home.

-Ray-

10-09-2008, 01:16 PM

Thanks

Like Greg said, you can get one at Sears, or Harbor Freight.

G8GTlawride

10-09-2008, 05:25 PM

Thanks I will be on the look out. Are the electronic ones any good?

Heres the POS I have. lol

http://s7.sears.com/is/image/Sears/00944690000?hei=250&wid=250&op_sharpen=1&qlt=90,0&resMode=sharp&op_usm=0.9,0.5,0,0

I'll be damned! Never did I think I would ever see another torque wrench like that! I had one just like it eons ago!

BlueJacket

10-09-2008, 05:33 PM

lol Sears has three diffrent ones just like that one.

piecesparts

02-08-2009, 02:43 PM

GRRRR8

02-08-2009, 02:51 PM

Noise/Vibration/Harshness. Basically a sound deadener for the DOD operations.

sharkie

02-23-2009, 09:23 AM

Here's a handy tip for gorillas out there that don't know the difference between in/lbs and ft/lbs: DON'T OVER-TORQUE THE BOLTS.

If you break an intake manifold bolt you will become very intimate with all of the parts, hoses, and electrical connectors on the top half of your engine. Ask me how I know...

Too bad the FAST intake isn't available yet.

BTW - Why is every vacuum hose connector and electrical plug different on these cars? Each one is like a mini rubik's cube for us non-certified types.

Executor999

02-26-2009, 12:15 PM

I need to ask cuz I'm about to do this. Your instructions only say to remove four 8mm bolts (black bracket in rear) and four 10mm studs. There is no reason to loosen the other bolts that hold down the intake manifold correct? Also why loosen and remove the 8mm bolts at all if the intake cover is being held down by only the four 10mm studs?

Thanks

GRRRR8

02-26-2009, 01:26 PM

To lift the fuel rail up and to retorque the intake evenly.

Executor999

02-26-2009, 02:11 PM

So all the bolts that attach the intake should be loosened, but only the four rear ones should be removed as well as the four studs should be removed. Is that right? Thanks again.

GRRRR8

02-26-2009, 02:18 PM

Correct. The rears are removed as the metal brackets cover the fuel line.

99-LS1-SS

02-26-2009, 02:25 PM

Ok, now I'm confused. The four studs in the back come off as well as the nuts? I was getting ready to start this.

Executor999

02-26-2009, 02:45 PM

The four 10mm studs hold down the intake cover. They need to be removed. The eight 8mm bolts hold down the intake. All eight need to be loosened but only the two (on each side) in the rear are removed because there's a bracket that holds down the fuel line. At least that's how I understand it.
http://www.howervision.com/g8/intake.jpg

I borrowed this pic from Crazy Paul. Okay so maybe there's ten 8mm bolts that hold down the intake. The 8mm bolts are removed in this pic, but the four 10mm studs are shown. Gives a clearer picture of what's what. :) Ignore the green arrows. Oh, and the four 10mm studs are actually bolts in this reference image.

EcoBrick Bob

02-26-2009, 05:11 PM

89 INCH POUNDS ---- NOT 89 FOOT LBS... You are not installing a WHEEL!

Executor999

02-27-2009, 06:07 PM

Success! I removed my intake cover today. One edit I would make is regarding an 8mm bolt in the middle on the driver's side that holds a bracket that connects to the 10mm stud next to it. I had to remove that bolt also in order to pull out the cover successfully.

Also, I noticed that when I removed the 8mm bolts in the back, the ends were wet with gasoline. Hope that's normal. No leaks of any kind during removal or afterwards.

-Ray-

02-28-2009, 03:07 AM

99-LS1-SS

03-01-2009, 03:46 PM

My harness was real tight. I just did it to make sure. I would say if the rail gives you ample space to slide it out, skip it. If not unclip them.
Just took mine off and my harness was tight as hell! It didn't want to come out. It's raining, sleeting and snowing here so I can't drive it right now. Does taking the cover off do anything for the sound?

G8GT721

03-01-2009, 03:49 PM

Just took mine off and my harness was tight as hell! It didn't want to come out. It's raining, sleeting and snowing here so I can't drive it right now. Does taking the cover off do anything for the sound?

i didn't notice any change after, but i have a rotofab and exhaust so it may have drowned out any sound change if there is any

GeorgeInNePa

03-01-2009, 04:18 PM

Just took mine off and my harness was tight as hell! It didn't want to come out. It's raining, sleeting and snowing here so I can't drive it right now. Does taking the cover off do anything for the sound?

Those of us with the DoD lifters really notice the noise from the valve train now.

You won't have to worry about that.

G8GT721

03-01-2009, 04:30 PM

Those of us with the DoD lifters really notice the noise from the valve train now.

You won't have to worry about that.

this is true at idle i can hear tick tick/ tap tap noise outside the car, but no additional noise while driving around could be imo

99-LS1-SS

03-02-2009, 06:27 AM

Charlie,
If one injector isn't in properly will you know it at idle? I think I got them all in and the car started and idled fine but the garage still smells like gas. Also, when I lifted the fuel rail gas seemed to only come out of the first passengers side injector. Not sure if that means anything or not.

NYG8GT

03-21-2009, 08:58 AM

Just did this myself today. It was a pain getting it to slide out the first half, it really didnt wanna budge at the back! I eventually got it after a few mins of fighting. Im hoping this helps keep the intake a bit cooler in the summer months. I'll probably revert back to the silver engine cover in the winter to keep some heat in for faster warm ups.

Crazy Paul

04-05-2009, 04:06 PM

Some people are having trouble visualising the Intake Cover and the aim of this mod. I'll try and explain here.

Here is the L76 engine with the Beauty/Noise cover still installed. See how the silver fuel rail crossover pipe appears to be digging into the intake manifold (centre of pic). That is actually the Beauty/Noise Cover that the fuel rail crossover is almost touching.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/DSC00175_640.jpg

Here is an LS3 intake manifold with the Beauty/Noise Cover still fitted on top.
Notice the 2 brass (goldy coloured) female bosses on either side of the intake and how the 4 "feet" of the cover locate over them.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/112_0709_07zLS3_intake_manifold.jpg

The plastic beauty/noise cover, see the locating "feet" on either side.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/LS320intake20cover20seperate-1.jpg

Underneath the removable beauty/noise cover is a foam pad piece.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/LS320intake20cover20underside-1.jpg

Here is the beauty/noise cover and foam pad completely removed from on top of the actual intake manifold.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/0706081817a.jpg

With the Beauty/Noise Cover removed you will now have an air gap between the bottom of the silver fuel rail crossover pipe and the top of the actual intake manifold. Green Arrows show where the Beauty/Noise Cover and foam padding used to live.
http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/P1010009-1.jpg

Crazy Paul

04-05-2009, 05:36 PM

The Beauty Noise Cover is located underneath the Fuel Rail.
You've seen above how the 4x "feet" of the cover locate over the attachment bosses for the fuel rail.

To get the removable Beauty Noise Cover out it is necessary to loosen various fasteners as posted previously in this thread. It is also necessary to remove totally 4x studs which hold down the fuel rail....then lift the fuel rail upwards, the 8x fuel injectors will remain attached below the fuel rail and slide upwards out of the Fuel Injector Bosses in the intake manifold.

http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/5b10_1X.jpg

http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/LS320intake20X.jpg

Here is the view of the Fuel Rail/Injector/Injector Boss relationship when everything is bolted down normally.

http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/P1010149X.jpg

Wider View

http://i2.photobucket.com/albums/y20/PerthPurplePenguin/car%20parts/L76/P1010130X.jpg

08G8V8

04-05-2009, 07:32 PM

Thanks Paul. I think I can follow this. I will be looking at doing this once I install my Vararam later this week.

zepcom

04-10-2009, 08:51 AM

Agreed; I'm not very mechanically inclined, so with Crazy Paul's "enhanced writeup", I will be tackling this project this weekend, to support my new split holden covers that I recently bought!!

:woohoo:

--zepcom

grandmacpubah

05-16-2009, 04:08 PM

paul ftw...there are some like me who over analyze and need pictures :D

timg8

05-16-2009, 09:27 PM

Thanks Paul, that was really a great pictorial that even us old timers could understand :stooges:

VENOM

05-24-2009, 06:50 AM

im still confused and scared to try to do this. i got a CF intake cover, so I want to remove the black cover and put this cover on. but i got no idea what everyone is talking about :(

GRRRR8

05-24-2009, 07:31 AM

I am not sure what the question is. You must becareful when torquing these bolts. If you replace them with mine they will not break.

-Ray-

05-24-2009, 09:22 AM

im still confused and scared to try to do this. i got a CF intake cover, so I want to remove the black cover and put this cover on. but i got no idea what everyone is talking about :(

You got a CF valve cover or engine cover. The intake cover is something else.

Gris

05-24-2009, 09:53 AM

How hard is it to get the 4 studs out?

-Ray-

05-25-2009, 03:52 AM

How hard is it to get the 4 studs out?

Mine came right out.

Devilish34

05-25-2009, 05:02 AM

Might do this today after I rotate the tires and inspect the rear diff and such.

Devilish34

05-25-2009, 02:01 PM

What do those black brackets do?? They appear to do little
(protect fuel rail ends) if anything

-Ray-

05-25-2009, 05:20 PM

That is why they are there. To protect in a frontal collision.

steve b.

05-28-2009, 04:54 AM

why would you remove the intake cover it looks good the way is is

Devilish34

05-28-2009, 04:58 AM

heat soak... Between the big silver lid and the intake cover there is about an inch of foam
that will trap heat

steve b.

05-30-2009, 05:45 AM

i am going to try this today hope i wont mess up wish me luck steve b.

GRRRR8

05-30-2009, 05:54 AM

DO NOT OVERTIGHTEN!!!!! 89 inch lbs.

Devilish34

05-30-2009, 05:56 AM

DO NOT OVERTIGHTEN!!!!! 89 inch lbs.

Was it in the original post first to 44lbs then to 89lbs?
Starting with the bolts in the middle then work your way out

wreckwriter

05-30-2009, 06:12 AM

Was it in the original post first to 44lbs then to 89lbs?
Starting with the bolts in the middle then work your way out

http://forum.grrrr8.net/showthread.php?t=1027&highlight=manifold+torque&page=2

grandmacpubah

05-30-2009, 08:21 AM

efff me I only tightened them down to 44 in lbs....

Devilish34

05-30-2009, 10:24 AM

efff me I only tightened them down to 44 in lbs....

opps

Devilish34

05-30-2009, 10:25 AM

http://forum.grrrr8.net/showthread.php?t=1027&highlight=manifold+torque&page=2

Thats good to know if I ever remove the intake.....

SpeedRacerX

07-18-2009, 10:34 AM

Help! I'm in the middle of doing mine - followed the steps but my injectors/fuel rail will not budge!!!!! Feels like I'm about to pop something off hard and end up spraying fuel all over the place.
Anybody out there help me figure out what I'm doing wrong!?!?
Thanks,
Randy

SpeedRacerX

07-18-2009, 12:51 PM

Whew! I'm done. Charlie called me and got me straightened out. Injectors were TIGHT. I did the upward wiggle and they popped up. A little pain getting the cover out from underneath the rail but it made it. Did run into a problem torque-ing those little bolts. All but one torqued fine. I friggin popped the last one - one that holds the driver side back black bracket on. Muthahumper. :puke: Another call to Charlie and he talked me down off the ledge. Those bolts are t-r-a-s-h and I was using a brand new, albeit $40.00, damm torque wrench.

Anyway, everything is fine. I will have to get it fixed. That will give me another reason to get the ported intake manifold - so I can get the broken bolt out. :secret:

Decided to take the car to my normal - post mods - "test runway." A nice stretch of 295 South heading toward Delaware. Figured I would stress test it from standstill and on the highway.

What do you know, a 2008 Mitsubishi Lancer EVO came up on me as I was entering the highway and I knew he wanted to go. The first run as I was easing up past 60, he came up behind me and tried to pass, I nailed it down and stopped that and pulled away from him: he "sorta" stayed with me to 120 (not). The next run I came up on him after clearing slower traffic at about 70, I saw his puff of smoke and his tail drop so I nailed it, pulled past him with no problems. Both runs I pulled on him badly up to 120 & 130+. Shhh. He gave me a wave when I departed from the highway.

Felt good given the broken bolt earlier.

Sure honey, I'll be happy to take you to dinner now.

Thanks Charlie for all your help! I have a feeling I'll be calling you again some time. :)

GRRRR8

07-18-2009, 01:11 PM

Very nice meeting you Randy. Sucks about the bolt, but thats life.

bobyoung

07-18-2009, 03:00 PM

Very interesting thread, think I'll be trying this once I get a torque wrench. Maybe tomorrow.

SpeedRacerX

07-18-2009, 05:19 PM

Very interesting thread, think I'll be trying this once I get a torque wrench. Maybe tomorrow.

It's so nice not having that cover on there - looks so much better now.

About the torque wrench. I bought one that went down as low as 10 foot pounds. I was able to get it as low as 7.5 foot pounds according to the markings but I don't trust it.

For this job, get a torque wrench that can measure in Inch Pounds - it will be safer considering how fragile the bolts are. This thread calls for 44 inch pounds to start and 89 inch pounds to finish.

Even still - as I found out the hard way - don't trust the torque wrench even when all seems set properly. Carefully feel for the turning and when it begins to seem weird or that it's still turning but you'd swear you should have heard the "click" from the torque wrench already...stop. Stop right there. Any more and you risk snapping these cheesy factory bolts.

As long as you are very careful when you put the bolts back in, you should be fine and this mod is SOOOO worth it.

PaFromFL

07-18-2009, 07:43 PM

Even still - as I found out the hard way - don't trust the torque wrench even when all seems set properly. Carefully feel for the turning and when it begins to seem weird or that it's still turning but you'd swear you should have heard the "click" from the torque wrench already...stop. Stop right there. Any more and you risk snapping these cheesy factory bolts.
I had a similar experience torquing the bolts that attached casters to Sears Craftsman tool chests. About every fourth bolt would not torque to the specified in-lbs. Fortunately, the bolts did not snap and no real harm was done to the plastic-feeling nuts inside the cabinets. I dropped the torque setting by about 15% and all was well.

blackbirdws6

07-26-2009, 09:49 AM

I just did this and man was it a piece of cake. I just need to take the car for a ride to see if it sounds any different but I can certainly see the thermal benefits of doing this. Nice mod and thanks for everyones pics.

Eric_GT

08-19-2009, 08:14 AM

GRRRR8

08-19-2009, 08:26 AM

PM Sent.

Eric_GT

08-19-2009, 08:26 AM

Sha-Zaam! Got it. Once I paged back through all the torque wrench and socket wrench talk (lol)...I found Crazy Paul's pics.
Many thanks!!!!!!

SpeedRacerX

08-19-2009, 08:33 AM

Guys I am pretty concerned with the injector removal part. I am ready to go and prying with a screwdriver yet I am hearing plastic creak. Kinda scary.
Does the entire thing pop out of the head?
Should i pry harder? The screws are all out and I have the wire loom unhooked from the fuel rail.

Eric, I just went through it a month ago...see posts. I had Charlie on the phone when I reached the same point that you are.
Make sure your key is off (no fuel).
I ended up NOT doing the big screwdriver thing because it felt and looked like I was going to break something or damage the plastic.
Instead, I just gradually wiggled, with an increasingly stronger upward wiggle movement at each injector and the fuel rail. It feels like they are going to POP off - sometimes they do but really it's just the O-ring on the injector stuck inside the housing. It will squash itself out and not really pop. Wiggle and pull up with increasing force and they will work themselves out. But since there are 8 you kind of have to wiggle them all up and out at the same time or try to work front to back, back to middle, etc and once they loosen, they'll all pop up...

SpeedRacerX

08-19-2009, 08:42 AM

Didn't see your post Charlie about your PM to Eric. I must have been typing.
Sorry...

GRRRR8

08-19-2009, 08:44 AM

No worries. Any input is always welcome, that way they have other options as well.

Eric_GT

08-20-2009, 05:03 AM

Yeah, thanks guys! Man, these covers look sweet! I also added the new oil cap as it appears many other did too. I had to use a sharp steak knife to make the cutouts. What a pain! But I didn't have a small saw to use and was too impatient to go out and buy one. lol
I slowly torqued all the screws back down. I didn't use a torque wrench; just did it the old fashioned way- tighten with a small ratchet with hand up around the ratcheting end until snug. I barely went tight. I'll check them in a week. Better than snapping one off- ouch!

SpeedRacerX

08-20-2009, 05:27 AM

Glad it worked out. Now, what "covers look sweet?" Did you add something after taking the other one off?

Eric_GT

08-20-2009, 09:59 AM

Oh yeah...I removed the intake cover in order to add the 2 piece Holden engine covers from Crazy Paul.
They look sweeet!

99-LS1-SS

08-20-2009, 10:18 AM

Pictures or it didn't happen. :)

SpeedRacerX

08-20-2009, 11:18 AM

Yeah Pix. Plus, the weight of those covers just totally negated the performance gains of your new Headers! :brock::drunk:

Eric_GT

08-20-2009, 11:59 AM

You guys are a pain in the ass! :nah: lol
http://forum.grrrr8.net/attachment.php?attachmentid=3015&stc=1&d=1250798336
http://forum.grrrr8.net/attachment.php?attachmentid=3016&stc=1&d=1250798336

SpeedRacerX

08-20-2009, 12:11 PM

Looking good...

Eric_GT

08-20-2009, 12:24 PM

Thanks!
Yeah, I worked on it for about 2 hours yesterday. I may buy a small saw and clean up the cut outs a bit more= get a better angle on them.

It was funn though, because when my son came out at the end, he said WOW THAT LOOKS COOL DADDY! NOW THAT LOOKS LIKE A V8! hahahah
He also loves the new headers. Really gives it a ballsy sound when you get on it.

99-LS1-SS

08-20-2009, 12:25 PM

Glad to see you are happy with your mods Eric. I like the 2 piece covers. I think they look sharp.

GRRRR8

08-20-2009, 02:07 PM

Monty

08-20-2009, 02:53 PM

I used a table grinder on mine it took about 5 min. I still have to take off about a 1/4in. When the hose expands it lifts the cover.

http://img9.imageshack.us/img9/7323/1000054j.jpg

http://img8.imageshack.us/img8/1274/1000056g.jpg

Eric_GT

08-20-2009, 06:04 PM

Didnt think about that Monty. I have a grinder but was afraid to experiment too much. I could see just tearing a big crack into the cover. :(

And yeah, I saw the heater hose relocation link, Charlie. But hell, that's even more time spent! And I already have little to no patience. :D

Marauder

09-07-2009, 10:30 AM

Interesting thread, I'm considering doing this. I have already installed the Vararam and the HSRK and have purchased some hoses so I can get those off of the top of the engine but I keep wondering:

How much of an issue is heat soak or are these mods more for aesthetics?

Monty

09-07-2009, 11:26 AM

This is what the cover looks like inside and out. (taken quickly with a camera phone)

http://img442.imageshack.us/img442/1219/photoak.jpg

http://img3.imageshack.us/img3/2129/photoba.jpg

Notice the heavy rubber insert.

http://img215.imageshack.us/img215/6745/photocu.jpg

djo165

10-18-2009, 11:25 PM

I finally got around to installing my hose relocation kit, removing the intake cover, and installing my two piece Holden engine covers and radiator cover. Thanks to Charlie, Crazy Paul, and everyone else who offered some insight into doing this mod. Y'all rock!

http://i95.photobucket.com/albums/l126/djo165/G8/2009Oct18002.jpg

MoonPie

08-08-2010, 07:15 AM

I know this is an old thread. I did this today with my organic torque wrenches -> instant death and ten seconds faster: my left and right hands...

american_kestrel

11-30-2010, 07:34 PM

I know this is an old thread. I did this today with my organic torque wrenches -> instant death and ten seconds faster: my left and right hands...

MoonPie, what are you talking about "instant death" and "left and right hands"? Did the mod not go well for you?

polo

11-30-2010, 07:47 PM

MoonPie, what are you talking about "instant death" and "left and right hands"? Did the mod not go well for you?

He doesn't even know what he's talking about half the time :)

GWNG8

04-13-2011, 11:33 AM

Is this cover just plastic?

-Ray-

04-13-2011, 01:34 PM

Is this cover just plastic?

Yes, the intake is plastic.

MoonPie

04-14-2011, 08:23 AM

MoonPie, what are you talking about "instant death" and "left and right hands"? Did the mod not go well for you?
I hit you with my left hand and instant death. I hit you with my right hand, 10 seconds faster.

He doesn't even know what he's talking about half the time :)

Polo
http://i950.photobucket.com/albums/ad341/VMIMoonPie/d8e1792f.jpg

BluYa76

04-14-2011, 05:35 PM

I hit you with my left hand and instant death. I hit you with my right hand, 10 seconds faster.

Polo
http://i950.photobucket.com/albums/ad341/VMIMoonPie/d8e1792f.jpg

lol

GWNG8

04-18-2011, 01:21 PM

So if one is removing the foam, is there any reason to put the plastic cover back on overtop of the plenum?

Crazy Paul

04-18-2011, 03:47 PM

texn884

04-18-2011, 06:32 PM

Id like to do this but I know I would mess something up.

aabry

03-27-2012, 11:09 PM

I started to do this, then read further. I read that the lifters and engine ticks and taps are more apparent with this cover off...so that decided it for me. I've already got a tick while DOD is engaged...sounds like a diesel truck in AFM mode, but goes away when all eight kick in. Several ticks while at idle, and the infamous alternator whine. GRRRR! The holden covers work with the intake cover on there right? I'd like to do the covers, oil cap and radiator cover for sure...

Crazy Paul

03-28-2012, 12:12 AM

The holden covers work with the intake cover on there right?
If you are talking about 2 piece 6.0 engine covers then NO, the acoustic cover above the intake manifold has to be removed permanently to fit them.
14624

msb7144

05-24-2012, 06:38 PM

Gonna do this mod as well, I cant understand the reasoning behind.......rubber-plastic-gap-rubber-plastic (in order from engine upwards of course) is this not overkill? On another note, I cant believe you guys that bought the 6.0 covers and then cut them............thats crazy! Get the heater hose relocation kit and take 1/2 hour and make it look 100% cleaner AND NO CUTTING new covers!

TooManyHobbies

11-22-2012, 10:26 PM

How do you change valve covers on a 1995 firebird ?
My valve covers are leaking how do I take the intake off my v6 firebird?

Throw a lit match down the gas fill pipe.

k20dajuan

11-14-2013, 09:17 PM

hmm didnt reakize there was 2 covers

Chewy

11-15-2013, 05:13 AM

Executor999

11-15-2013, 05:26 AM

I literally drove my car home 5 years ago, popped the hood and did this mod and a CAI first. I did many of Charlie's mods including getting a set of his ARP bolts just a few months ago to put my top end back together with.

You'll be missed Charlie!

Chris

This is a nostalgic thread for me too since it was my second mod after the Rotofab, both of which I accredit to Charlie. I reread it over and over because I was so scared I wasn't going to be able to remove the cover without causing a gas leak of some kind. :)