Originally Posted by BaseDrifter

Drain coolant (or don't, but it will be messy), disconnect coolant lines and level sensor plug, replace tank, refill coolant and bleed system.



I like to use Goo Gone to remove stickers. Be careful about rubbing too hard and removing the paint, the clear coat is very thin in the engine bay.



WD40 + rag + energy. If that's not enough, dab a little acetone onto the grime. Still not enough? Lightly use a wire brush, you can scratch the manifold this way though.



Remove caps, acquire silver sharpie, trace. Take your time, don't color outside the lines.



See above. WD40 cures all.



Remove fasteners one by one and match at hardware store with stainless steel replacements. I suggest doing this little by little so you don't bawk at the total price. I probably spent $40-50 on stainless steel bolts, nuts, and washers.



WD40 + wire brush. Or just replace it. Best to use Norma brand (or any non-segmented brand) hose clamps.



See here.



See above.


I spent ~3 years working on my intake manifold on and off. It was something I would spend an hour on here and there when I was bored. I used a grinder to knock down the big stuff and then used a rat tail file to remove the casting marks between the runners and shape the curves. After that I used an air powered sander to run through the grits and polish it out. Then I bead blasted it and ran it through a parts washer to clean it out.

The result: