I'm doing the plenum repair on a '94 5.2L and I've watched quite a few videos and read guides before tackling the job. I have all of the intake manifold bolts out and I think the keg should be ready to come out - I'm going to vacuum all around it first thing tomorrow morning and attempt to take it out.

I have way less room at the back of the intake manifold and I'm wondering if there's any difference in the 94 model? I can't find/understand any difference when reading the service manual.

It seems like there's an extra device and wires to the left of the distributor cap and it feels like it has resistance when I'm trying to pull it out with all of the bolts removed. I'll get some pictures up in my build thread tomorrow but I was wondering if anyone had any ideas? I know this is a bit vague but I'm trying to make an action plan for tomorrow morning.

Edit: Also there was an additional device on the back right bolt of the fuel rails that I didn't recognize.

 

94 intake will have an EGR valve. There is a pipe that runs from the passenger side exhaust manifold, to the rear of the intake, gotta get that loose before the intake will come out.

 

Thanks I removed the two bolts holding the thing above it with the two vacc lines and it came out with a wrench. Just got the intake off and it looks like a freaking sewage plant in here:

 

Not really unexpected..... shows signs of neglect. Use a shop vac to pick up as much of that crap as you can.

 

Is the bracket and vac house, electronics on the back right fuel rail bolt, and other vac house all part of the EGR?

Is it recommended to remove this or should I leave it all?

 

Should be a valve of some description on the drivers side of the intake, toward the back. That is the cannister purge solenoid. Not part of EGR system.

Also, your oil pressure sensor looks like it had a bad experience there. Replace that before putting the intake back on. (not to mention cap/rotor/wires, it doesn't get any easier than it is right now.)

 

jesus how many miles are on that truck

 

Only 140k and it's a 94. The age and combination of it not being driven that much (around 10k per year average) led to this I believe. The previous owners were not neglectful but definitely not aware of the plenum issue. I don't think it was driven on the highway very often.