How in hell do you install the billet tubes into the upper intake manifold?

There's no problem to install them into the intercooler, just the upper manifold it's too tight of a fit. Heck they don't even fit without o-rings, I don't see how they can fit with the o-rings in place.

 

I wish I could see what you are talking about I'm pretty good at fittin things.

 

i forget how exactly it goes together. i do remember greasing up the o rings though but somethings gotta be wrong if it wont go together even without the o ring

 

Yeah I lubed the o-rings and it was a no go so I removed them to see if they fit and it was a no go too. Tried to fit them into the intercooler openings and both fit fine with or without o-rings.

I guess I need to do a bit of clearance on the manifold side. Just found an old post from another member (duckhunter1999) and he mentions the same problem.

Schino, do you remember if it was a tight fit?

The tubes go all the way into the intercooler when I remove the o-rings and there's a bit of space (less than a mm) between the billet tube and where it connects. Once I install the o-ring it goes in with a bit of pressure but nothing drastic as I can get it installed with one hand.

 

i vaguely remember doing it. i was sitting on the porch when i put it all together i do remember that! haha it was a light press in, something you can do with your hand if i remember correctly. the tubes are same size both sides correct?

 

Yes, they're the same on both sides. If you did it on the porch it was easy I guess.

Running to a friend's machine shop as I type haha want to get it done over the weekend.

 

 

Hmmm . Mine went right together, did you get it figured out yet?

 

Yes it's done, the first idea was to bore the manifold to the tube size but ended up removing a tad under 0.02" from the billet tubes (thanks shino) as it was the path of least resistance.

Haven't finished the install due to work but tomorrow should be done, the thing that scared the most (fuel pump) was done last Sunday that took me 1.5 hours including lifting the bed 8" from the frame to gain access to the fuel tank, man it was easy.

Will post results once it's done.

Forgot, a friend helped with the fuel pump, it was impossible to lift the bed by myself.

 

Good deal man!

Yep without help or lifting devices the bed is hard for one guy to pull.

Sorry I've not been much help, I'm working Wayyyy too much!