:help: Knee deep in LLY boost gauge install and ran into a snag. To remove upper intake manifold casting per Kennedy's install pictures, it looks like 5 bolts and cut a zip tie. Question is - Is there any precautions to take when reinstalling the casting? Torque values? New gaskets? Need to know before I take it out.
Pyro probe install was a piece of cake with all of the expert guidance given on this site. Hardest part was getting the guts up to drill the first hole.

Thanks for the help. Dean

Dean- No need to remove the manifold. Just remove the intercooler boot that attaches to it as well as the air intake tube for clearance. You will then have room to drill and tap. Make sure you drill down far enough to where the chips will just fall out. Its a good idea to wipe them out also after drilling/tapping. Hope this helps.

DSTRBD,

I must be doing something wrong. I have the big black intake tube out and have removed the rubber boot off of the aluminum/lower intake manifold. There is no way to get a drill in there to drill the hole. The air conditioner line is in the way. It would take a angle drill and a very short 21/64 th's bit to do it installed.
Am I missing something?

there should be no issues with gaskets since its only air that goes through there, unless it breaks when you remove it or something then of course replace it. So remove the casting, put it in a vice, drill and tap, and you are done. as far as torque specs on reinstall you might want to just stop by an autoparts store and open a Haynes manual for the specs- or just call them,they can find it for you. from my experiences intake torque is usually 15-25ftlbs, but please verify this with a manual.

When I did mine I had to remove the intake and cut the black zip tie. I reused the gaskets and didnt know the torque specs on the air horn - but I think I got it alittle tighter than 15-25ft :D But Briano is right you might want to check the specs and put them back to factory torque.

Thanks all,

Worked like a champ. Popped it off, drilled and tapped and re-installed. Gaskets are metal and would be difficult to damage. Casting is probably a 1/4 inch thick and made for a solid mount and no extra cost. I still don't see how it could be done on the truck. Maybe a LB7, but definately not on a LLY. Oh well, like I said install complete. Thanks again.

There is room to do it on the truck. Yes, the AC lines are there, but you dont have to drill it on the side. We just did one last weekend without removing the manifold. Worked like a charm. Either way is fine, just easier to leave it on. Glad you got it figured out.

Get the "Super Diesel" boost boot and don't worry about all that mess. I did, and what a slick product ! Just remove stock manifold black boot and replace with the new boot with multi tap ports. Nothing could be more simple, and it looks great too. It's money well spent !


Just contact Super Diesel for more info !

PS: No I am not a paid advertiser for the product, I am just a satisfied customer !):h

4day4me

Get the "Super Diesel" boost boot and don't worry about all that mess. I did, and what a slick product ! Just remove stock manifold black boot and replace with the new boot with multi tap ports. Nothing could be more simple, and it looks great too. It's money well spent !

4day4me
if I had not install the Attitude that includes boost monitor, I would purchased this product. Very well designed and is perfect for just this type of thing.