I am really in a jam...the bolts in the rear of the housing are to long. They are restricted from coming all the way out, the intake manifold is blocking the bolts. Also it appears the knock sensor wiring is resting on top of the housing causing it to be stuck and jammed between the housing and the intake manifold. I have broke apart the housing down to the bolts, and have been struggling ever since. Is this always this difficult? I know lots have done this process before, what is my problem? I was thinking to chisel my around the bolts...any help with ideas...Sorry guys, I keep asking for help.

 

When I changed my housing I had to loosen and remove the ten bolts for the intake. The gaskets can be reused.

 

Thanks Mike. Is it just a matter of clearance? I would not have to remove the intake all the way? Thanks again for your thoughts.

 

It was clearance. You only need about 1/8" more than you have now. I loosened, but did not remove the rear most bolts, but took out the front eight.

 

OK. I will try that, and thanks Mike.

 

Releasing the bolts on the intake as MikeBaker3 suggested work well. I did use cap screw heads at 20m to prevent the intake clearance issues in the future. I have now replaced the waterpump, T-stat and housing (metal) and bypass hose. Not had a chance to check it out yet, update to follow. TY to MikeBaker3.