I replaced the upper intake manifold gasket yesterday. See this thread. It went pretty smoothly for the most part. The toughest part was removing the old gasket, it would only come off in pieces and some areas around the bolt-holes had to be "chisled" off. I followed the Sam Jelinek Procedure. I'd like to clarify some aspects of that procedure, if I may:
1. The EGR tube bolt (~22mm) does not need to be disconnected, however we did remove the EGR valve to allow less obstruction. This is a good time to check the pintle travel and spray some carb cleaner in the orifices.
2. The fuel injector wire-clips were tricky. The blue retaining clips get "popped" half way out, then you can depress the tab and pull the wires straight off the injectors. Have fun taking off the rear DS one. <img src="/forums/images/graemlins/drunk.gif" alt="" />
3. After disconnecting the fuel injector wires the fuel rail needs to be lifted so you can get to the front IM bolts and move the port cover out of the way. The injectors lift straight out of the ports together with the rail.
4. The fuel regulator and lines will prevent the driver's side rear from moving too much. Just be careful that you don't spring a leak. <img src="/forums/images/graemlins/shiner.gif" alt="" />
5. And finally, while the IM bolts get torqued to 17 ft/lbs, this is way too much torque for the throttle body bolts. This is the "only" <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> place where I had trouble. One of my upper bolts sheared. <img src="/forums/images/graemlins/angry.gif" alt="" />

Perhaps this could have been avoided if I torqed 'em rather than my 6'5 220+ lb Semper Fi buddy <img src="/forums/images/graemlins/mrt.gif" alt="" />, but never-the-less I have half of a bolt threaded into the damn thing. I think everything will be OK, but knowing this imperfection is going to kill me. Does anybody know the (proper) way to get a sheared bolt out of a threaded hole? Am I best off just leaving it alone or do I need to find a used/junker part($$$)?

And after all this, I now have confirmed that my lower IMG is leaking. I continued to hear the sucking sound after replacing the upper IMG, so a little more carb cleaner and now I have next weeks project identified. So it appears that the lower IMG is doable. I think I will have to remove the EGR tube and fuel pres. regulator this time, and possibly some other doodads, but all together it appears a lot like the upper IMG job. Has anyone who replaced the lower IMG run into any snafus? As an amateur mechanic am I asking for trouble??? <img src="/forums/images/graemlins/evil.gif" alt="" />
TIA,
Eric