There are 2 ways to remove it....

1. Take manifold off. Unbolt 4 bolts. Remove it. Reinstall manifold. (3/4 hour, if all goes well)
Will need tool provided for installation from Stillen or make own tool like i did.
or......
2. Unbolt 4 bolts. Pull out ic as far as possible. Tape off manifold area. Hack saw it off. Vacuum up any chips. (1/2 hour)

You'll shoot your eye out! ;) (christmas story reference)

Well some of us do spend $$ on ourselves (that way we get exactly what we want). Just purchased a Henry 45-70 that I have wanted. It should be here next week in time to put under the tree.

Henry is nice. I have a Marlin.

Yes, but be aware that on the far end of the Stillen heat exchanger it is attached to the inside of the manifold with strong double sided tape. When you pull the heat exchanger out the tape will come apart and some of it could fall down into the intake runners. To prevent any junk from falling into the engine I would remove the rear throttle body and run a vacuum hose in it to the rear of the manifold (where the tape is) so that any tape that tears loose will get sucked up by the vacuum as the unit is being pulled out.

I removed mine prior to installing the manifold because I went with the A2A from the beginning. You will have to really pry on it but it will come out.

Yes I just discovered this during our tear down. I went ahead and removed the black adhesive. Taking off the manifold is a PITA but it's really the best and safest way to take the internal heat exchanger to ensure that u get everything out and no components are actually left in there. I was blown away by how much space the internal intercooler took up in the manifold. With it removed there is a lot of room for air flow now....

Once ur pass the manifold removal everything else is a walk in the park. Gonna clean up my manifold before I proceed with the install. A2A kit should be complete in the next 2 days if anything.

What are you guys using to make a block off plate on the manifold, 3/16" alum plate?

Thought you were relocating mafs and running water setup.

I am, was just curious.

Rest of my parts hopefully show up next week so can start on it soon.

My god... No one knows the trouble I'm going through to get a damn spacer for my pulley. It's been past a month now and no luck. Build postponed until further notice :mad:

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Hi all, I need some help urgently.
As part of my Air to Air upgrade I've had my shop replace the stock Stillen SC pulley with a 2.8" Vortech hi traction SC pulley but they say they can't adjust the stock Stillen serpentine belt to fit/work and can't find a suitable replacement one.
Do you have any suggestions?

Get a 3" idler pulley.

Thankyou very much again TopZ. :tup:
My shop is looking into it now.

My shop just tried a 3.0" idler and the serp belt still can't be adjusted tight enough. Any bigger than 3" will have interference. Is there anything else I can do beside having to go ditch the 2.8" SC pulley and going to a 3.0"? :shakes head:

Need to go 3.0" on sc and 3.4" on jackshaft to keep that ratio and the same idler. Or 9psi serp side and one of the options above with the 3" idler, but that will spin it even faster.