Heads-Up to those installing FI on their FT86: Failure Point Addressed with Photos

[glamcem]

hmm..it seems like I'd better do this before I put my KW kit on the car, since it will be harder to reach and more work.. Thanks for the heads up

Can anyone post some better pics showing the best way to reach those hoses underneath the intake manifold or better yet create a DIY for this?

I think this thread should be sticky since it seems like many people run into same issue

[ecko04]

Originally Posted by glamcem

hmm..it seems like I'd better do this before I put my KW kit on the car, since it will be harder to reach and more work.. Thanks for the heads up

Can anyone post some better pics showing the best way to reach those hoses underneath the intake manifold or better yet create a DIY for this?

I think this thread should be sticky since it seems like many people run into same issue

Just let me say you absolutely don't need to remove the intake manifold to clamp the hoses. Removing the manifold adds additional work that just isn't necessary.

The best pictures are those posted by @rb6freak thanks to @ptuning turbo installation guide which states to clamp the hoses.

With the accessory belt off and the AC compressor sitting either on top of the manifold or the oil filter, with a shop light, you can get the job done in 30-40 minutes, depending on your setup.

I suggest clamping as soon as you remove whatever intake you're using whether its stock or CAI. At that time everything front of the throttle body is wide open (i.e. no intake charge pipe in the way, no big honking turbo, no supercharger, etc.).

With a supercharger installed this task becomes infinitely more involved as you have even less space to work with.

In any case these are the steps one would take in order to gain access to the vacuum lines to clamp.

Removing Stock Airbox

http://www.ft86club.com/forums/showthread.php?t=7975

Removing Accessory Belt

http://www.ft86club.com/forums/showthread.php?t=10227

With that done you can proceed to removing the AC Compressor.

There are 3 14mm bolts that must be removed in order to swing the compressor out of the way. 2 are below the compressor pulley, one on each side, loosen and remove these first. If you have a front mount turbo installed the best tool to use to remove these bolts would be a ratcheting wrench as it works wonders in tight spaces. The 3rd is behind the compressor, loosen and remove it last. The AC compressor can now be moved to the side.

You'll need at least 4 9/16" spring clamps and 3 1/2" spring clamps. I found the best tool for the job was a pair of long, skinny, but sturdy needle nose pliers. By far the most difficult clamp was the throttle body clamps. All the others are cake.

Refer to @rb6freak's post for the location of the hoses that will use the 9/16" clamps and 1/2" clamps.

http://www.ft86club.com/forums/showp...1&postcount=35

1 hose next to the port injectors - 9/16" clamp
1 hose underneath throttle body - 9/16" clamp
2 hoses underneath intake manifold at the EVAP solenoid - x2 9/16" clamps
2 hoses on top of intake manifold (underneath plastic boxer cover) - x2 1/2" clamps
1 hose behind motor on top of trans - 1/2" clamp.

Give each hose a nice tug and you'll notice they aren't going anywhere.

Reassemble in reverse order ensuring the accessory belt is seated within the teeth of each pulley before starting the car.

[glamcem]

Originally Posted by ecko04

Just let me say you absolutely don't need to remove the intake manifold to clamp the hoses. Removing the manifold adds additional work that just isn't necessary.

The best pictures are those posted by @rb6freak thanks to @ptuning turbo installation guide which states to clamp the hoses.

With the accessory belt off and the AC compressor sitting either on top of the manifold or the oil filter, with a shop light, you can get the job done in 30-40 minutes, depending on your setup.

I suggest clamping as soon as you remove whatever intake you're using whether its stock or CAI. At that time everything front of the throttle body is wide open (i.e. no intake charge pipe in the way, no big honking turbo, no supercharger, etc.).

With a supercharger installed this task becomes infinitely more involved as you have even less space to work with.

In any case these are the steps one would take in order to gain access to the vacuum lines to clamp.

Removing Stock Airbox

http://www.ft86club.com/forums/showthread.php?t=7975

Removing Accessory Belt

http://www.ft86club.com/forums/showthread.php?t=10227

With that done you can proceed to removing the AC Compressor.

There are 3 14mm bolts that must be removed in order to swing the compressor out of the way. 2 are below the compressor pulley, one on each side, loosen and remove these first. If you have a front mount turbo installed the best tool to use to remove these bolts would be a ratcheting wrench as it works wonders in tight spaces. The 3rd is behind the compressor, loosen and remove it last. The AC compressor can now be moved to the side.

You'll need at least 4 9/16" spring clamps and 3 1/2" spring clamps. I found the best tool for the job was a pair of long, skinny, but sturdy needle nose pliers. By far the most difficult clamp was the throttle body clamps. All the others are cake.

Refer to @rb6freak's post for the location of the hoses that will use the 9/16" clamps and 1/2" clamps.

http://www.ft86club.com/forums/showp...1&postcount=35

1 hose next to the port injectors - 9/16" clamp
1 hose underneath throttle body - 9/16" clamp
2 hoses underneath intake manifold at the EVAP solenoid - x2 9/16" clamps
2 hoses on top of intake manifold (underneath plastic boxer cover) - x2 1/2" clamps
1 hose behind motor on top of trans - 1/2" clamp.

Give each hose a nice tug and you'll notice they aren't going anywhere.

Reassemble in reverse order ensuring the accessory belt is seated within the teeth of each pulley before starting the car.

Thanks for the detailed reply.
I will definitely install all the clamps as you suggested right before the SC install to avoid double efforts.

While at it I'll try to take better pictures for those who might need

[Lonewolf]

Vote for a sticky so this thread doesn't get buried....

[Boss Paco]

You don't need to move the AC compressor. Just pull the throttle body. It's four 10mm bolts. And removing the solenoid with the 10mm nut on the back side of the manifold makes it so much easier to clamp. The throttle body being off also makes it easier to access the port near there. And, yes, a good pair or two of needle nose makes everything awesome.

[kiichiro]

Sticky this

[lexusb3]

Originally Posted by Boss Paco

You don't need to move the AC compressor. Just pull the throttle body. It's four 10mm bolts. And removing the solenoid with the 10mm nut on the back side of the manifold makes it so much easier to clamp. The throttle body being off also makes it easier to access the port near there. And, yes, a good pair or two of needle nose makes everything awesome.

EXCATLY what I did!

[kiichiro]

It's possible to do without pulling anything with the right hands

[glamcem]

Originally Posted by Boss Paco

You don't need to move the AC compressor. Just pull the throttle body. It's four 10mm bolts. And removing the solenoid with the 10mm nut on the back side of the manifold makes it so much easier to clamp. The throttle body being off also makes it easier to access the port near there. And, yes, a good pair or two of needle nose makes everything awesome.

Ok , yesterday after the track event I had some rough idle and stalls and today I noticed the sound of the leak. Although I have put clamps on all the other lines prior to my KW install it seems like I missed the one below the intake manifold. So where exactly I can find this hose since it's really hard to see it in the pictures of video? I'd rather not to remove the AC compressor since I have SC and pulleys in front of it.

Which one is the solenoid?Are you referring to a boost control solenoid included in one of those turbo kits?

[HRTROB]

Originally Posted by glamcem

Ok , yesterday after the track event I had some rough idle and stalls and today I noticed the sound of the leak. Although I have put clamps on all the other lines prior to my KW install it seems like I missed the one below the intake manifold. So where exactly I can find this hose since it's really hard to see it in the pictures of video? I'd rather not to remove the AC compressor since I have SC and pulleys in front of it.

Which one is the solenoid?Are you referring to a boost control solenoid included in one of those turbo kits?

It's located underneath the driver side of the manifold (left hand side). When I clamped mine, I tried first without removing the compressor but it was impossible, unless maybe you have really skinny hands.

Shine a flashlight on the holes in between the intake manifold runners. You'll be able to see the hoses from there. I used worm clamps on mine since I couldn't find any spring clamps. Tigthened them up using a screwdriver inserted through the holes between the runners.

Moving the AC compressor out of the way makes the job 100x easier.

[jamesm]

Best thing to do is just pull the manifold and completely remove the solenoid. Then you only have one place to cap/clamp. It's not a very difficult job, and will make sure the problem doesn't show back up down the road. If you don't do that, make sure that you use real clamps and not zip ties.

[glamcem]

Originally Posted by jamesm

Best thing to do is just pull the manifold and completely remove the solenoid. Then you only have one place to cap/clamp. It's not a very difficult job, and will make sure the problem doesn't show back up down the road. If you don't do that, make sure that you use real clamps and not zip ties.

I'd much rather remove the intake manifold if it only requires me to remove the TB and 4 bolts that connect the manifold to engine, is there anything else that needs to be removed? do you have the torque specs of the bolts that need to be removed?

Thanks again

[Cessblood]

Originally Posted by Boss Paco

You don't need to move the AC compressor. Just pull the throttle body. It's four 10mm bolts. And removing the solenoid with the 10mm nut on the back side of the manifold makes it so much easier to clamp. The throttle body being off also makes it easier to access the port near there. And, yes, a good pair or two of needle nose makes everything awesome.

I did the same thing

[jamesm]

Originally Posted by glamcem

I'd much rather remove the intake manifold if it only requires me to remove the TB and 4 bolts that connect the manifold to engine, is there anything else that needs to be removed? do you have the torque specs of the bolts that need to be removed?

Thanks again

I just used the first part of the innovate install manual as a guide. The only other thing I remember taking off is the shielding over the port injectors.