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2.5 Turbo Intake manifold removal

Transit Mk3, 4 & 5(smiley front) Forum. All Transits 1986 - 2000

2.5 Turbo Intake manifold removal

Postby JaruloPan69 » Sun May 17, 2026 11:18 pm

Any pointers on how to remove the bolt of the intake manifold that is almost completely blocked by the injection pump?

Is it at all possible without removing the pump first? I'd prefer not to since i'm worried about timing issues (car went into limp mode before when pump was just sligthly misaligned)

Tried all kinds of spanners and sockets, if i can get something on the bolt i dont have enough room to crack it open.


Any suggestions appreciated...
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Re: 2.5 Turbo Intake manifold removal

Postby dumper » Mon May 18, 2026 7:57 am

Have you tried heating a ring spanner up and bending it I had to bend it in a S shape I know I originally did it for the York engine can’t remember if I used it also on the di over the years bent loads of cheap spanners to undo near impossible fittings
2025 MK 8 L3 H3 Motorsport campervan
Past camper vans
1974 mk1 v4 with 2.0 pinto fitted
1986 mk3 2.5 di swb
1990 190 lwb 2.5 di
1998 100 lwb 2.5 di
2006 350 jumbo 135 tdci
2015 MK 8 L4 H3 motorsport campervan
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Re: 2.5 Turbo Intake manifold removal

Postby meerkatmag » Mon May 18, 2026 9:56 am

I've done this, i had to use a number of different size 13mm spanners and different socket wrench sizes with various extensions and flexible joints. It was a nightmare but it is possible.
1988 transit MK3 2.5 tdi with intercooler
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Re: 2.5 Turbo Intake manifold removal

Postby JaruloPan69 » Tue May 19, 2026 8:27 pm

Will try modifying some cheap 13mm spanners, thank you!
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Re: 2.5 Turbo Intake manifold removal

Postby V184 » Wed May 20, 2026 2:13 pm

13mm spanner with a flexy socket at one end snap on do them
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