I've got a 1991 and have the 2 bolts and one bolt holding the wire harnes out ok, but the wire harness and heater line make it very difficult to lift out. Is there a trick to this? How far does it have to lift before it will move laterally? And is there a hose I have to watch out for, not dropping into the engine? thanks!

I have a 91 240 and had similar problems when I attempted to remove the breather box for cleaning/inspection. My 240 also has an EGR Valve, adding extra cursing and skinned knuckles to the project. After 3 hours I had the breather box loose..but like you, could not twist/turn/rotate/lift the darn thing out. I did not want to risk damaging the heater core hose and/or heater core so I put it all back together :(

From what I have read, we can 'loosen' the intake manifold enough to make the breather box job much easier and simply SLIDE a new manifold gasket into place without ever having to totally remove the manifold. When I have all the parts on hand I am going to attempt it again.

good luck with yours.

I don't know about the 1991, but on my 81 it had to be lifted one inch before it would move laterally. The oil return line stayed in the block without moving out of its position at all. Wiggle the box upward carefully and watch under it with a mirror and light a few times as you work it up and out. Good luck.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock; 86 240, 129K

I always remove the intake manifold to get to the box (reinstall w/gasket). You will have to lift the about box about 1-2in higher to get it out of the drain hose.

Rats! Was hoping not to hear that, but can see why that would make it ALOT easier!

removing the intake manifold is much easier than it sounds. Disconnect the fuel line, tps harness, cables, and vacuum lines.