I'm in the process of removing my 1994 P72 intake manifold so I can get better access to my oil cooler to replace the o-ring, and also to replace ALL coolant lines on the engine. In order to get access to the bottom middle 2 nuts on the IM, I just went ahead and cut the oil cooler coolant lines so that I could get my ratchet up in there. I'm hoping I'll be able to get the new coolant lines on from underneath after I put the IM back on. I cut the lines because all the clamps on all those hoses were turned so that I could not get to them.

So now the question is, what if I have to remove the IM again for whatever reason? The 2 oil cooler coolant lines seem to completely block access to those bottom middle 2 nuts. Will I have to plan on cutting those lines every time and replacing them if the IM ever has to come off again? OBD2 GS-R's don't have the oil cooler, so those don't have those coolant lines in the way. Any tips on this? And no I am not switching to a Skunk2 IM. This is a daily driver and I don't feel like spending all that money on a new IM and all the additional parts needed to make it work (like chipped or different ECU).

 

I have removed my IM without cutting any lines. I can’t remember exactly how I got the tools in there to get the bottom two nuts off, but I do remember that it took forever. Is the oil cooler the little plastic box under the manifold (not the PCV box)? I remember that there were a couple small bolts connecting that box to the IM. I had to unbolt that box and move it out of the way to get to those two nuts.

 

What is wrong with just repositioning the clamp so that it will be easier to remove in the future? Maybe switch to a worm style clamp?

 

I've done a few on the 94 and 95 GSR motors. I've been able to get those two inner nuts underneath by squeezing a combination wrench down there from the side (Just reach your hand down the side of the intake manifold with the combo wrench, lock on the nut and turn left). You have just enough room to loosen the nut, then you can just rotate the nut off by hand.

It gets easier after a few R&Rs. I'm sure almost anyone can do it because I can do it and my arms are not small

 

No, the oil cooler is what the oil filter screws onto, and has 2 medium-size coolant hoses going to it. Those 2 hoses make a loop right above the oil cooler, below the lower IM nuts, and block access.

Yeah hopefully I will leave the clamps in such a position that I can get to them next time. The ones on the old hoses had the tabs pointing up (towards the IM above it), which made it impossible to get pliers onto them. Hence why I decided to just cut them.

 

http://www.thetoolwarehouse.net/shop/AP-9409.html

I have a set almost identicle to these. It sure does make life a little easier when you have hard to reach clamps