In another project we are working on a new manifold for the GENII MR2 Turbo. As that project nears completion, it was necesary to remove the GENII stock manifold. Since the car has plenty of custom part, some of the steps will be different from a stock MR2 Turbo.

First thing you should do is disconnect the battery, and relieve the fuel pressure. Once this has been done, the fuel rail can be removed. First remove the tower brace and continue removing the turbo hoses and throttlebody. You will need a 12mm wrench/socket in order to remove the fuel rail. Just before then, you'll also need to remove the hoses going to the fuel rail--this includes the cold start injector. We are running the hydra-nemesis EMS, so we took out the temperature sensor. You'll need to wiggle the rail after removing two bolts that hold it down to the head.

NOTE: Since we are putting a Caldina manifold on our GENII 3SGTE head, we removed the plastic cover from the fuel/tps/etc wiring harness, you DON'T NEED TO DO THIS.

There is a plastic cover over the wiring harness making things more difficult. We found that by pressing the plastic cover down, we could wiggle the rail over it. This allowed us to pull our fuel rail out.

Once the fuel rail is out, you'll have to start unplugging any hoses/connectors around the top of the intake manifold. Then you have to go below the car, and remove the intake manifold stays. They are two bars located below the manifold. We used 14mm socket, sometimes with an extension, in order to remove these. Something to note is that the harness gets bolted to one of these stays(bars), so you'll need a 10mm to remove it. Also remove the grounding straps that are on the intake manifold-they also use 10mm bolts.

Once the stays(bars) are removed, you'll need to unhook all the connections going below the center of the manifold. Some of these connections are: TVIS, Knock sensor, alternator wire, etc..

Once you have removed/unpluged the connectors/hoses, you can proceed to pull the wiring harness through the top center of the intake manifold. Another thing to note, is that the wiring harness connects to the timing belt side. You'll need to unplug the connectors near the a/c compressor, pull the harness back, pull up the plastic cover on top of the timing belt area. Once this is all done, and you have pulled the wires through the center of the manifold, you can pull the harness over to the driver's side, and let it rest there.

The next step will be interesting. You'll need to remove nuts/bolts around the intake manifold. We found that you can use a socket/adjustable wrench from on top, and below the intake manifold. The bolts/nuts were not too hard to remove, just be very carefull not to damage the heads, or the manifold is not coming out!!!

We left the center nut on, and checked around to see if any hoses/wires were connected to the manifold. It looked great, so we removed the nut and proceeded to remove the manifold. The manifold got stuck, and this is were we noticed that the wiring harness was still bolted to the manifold towards the driver's side. Using a 10mm adjustable wrench let us quickly remove the bolt, and finally the GENII MR2 Turbo was out:-) The TVIS had been modded previously, and you could see all the butterflies were gone, and the holes were welded shut.

The project took around 2-3 hours, and was not seriously difficult. Just make sure to be carefull with the nuts/bolts around the manifold--don't strip them, or you'll take much longer before taking the manifold out.

We managed to take the manifold out with no bolts getting stuck, so we were very thankful!