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        General >> How to do things! >> Inlet Manifold Part 1
        
(Message started by: PJDavis on Mar 30^th, 2013, 4:57pm)

Title: Inlet Manifold Part 1
Post by PJDavis on Mar 30^th, 2013, 4:57pm

Second time lucky!!! I'll post the story up here in two parts.

I put the car on ramps to facilitate getting underneath it for the removal of the bolt that holds the Manifold underneath.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3456_zps5aa4a4e8.jpg

I started by removing the large rubber pipe between the Throttle-Body and the Resonator-Box, jubilee clip both ends.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3461_zps26d570c9.jpg

You can get at the four Torx screws (T30) that hold the Throttle-Body on without removing the throttle-cable/cruise-control cable plate, but I first removed the cables-plate held by two Torx 30 screws, one facing the front of the car and one facing the off-side. You can see the Throttle-Body with the two screws replaced where they hold the cables-plate on.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3462_zps0eabe248.jpg

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3464_zpsaf8e789d.jpg

(Do yourself a favour, get one of those ‘Ariel-type retracting magnets’)
I then removed the throttle body, four T30 screws.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3468_zps37849c32.jpg

If you didn’t want to loose all your coolant, then you would just remove the thermostat housing, (this is covered elsewhere on the site) three M6 Hex-Head screws, using a 10mm socket/spanner. I was doing a complete refill and chose to drain all the fluid out using the bottom radiator hose, pictured with the squeezy clip. I used parrot-nose-pliers for squeezing.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3459_zps511aaf44.jpg

All the water now is drained. I was also putting a new Fuel-Shut-Off-Loom on, so I removed all the wiring from the top of the injectors, along with the rest of the loom. Undo the ten bolts that hold the centre-top-cover on over the spark-plugs M6 bolts using a 10mm socket/spanner. Disconnect the small clips that go onto the coils, and the camshaft sensor, and the one that is on the fourth injector closest to the bulkhead. Disconnect the three remaining electrical contacts on the injectors and move all the wiring to one side carefully! At this point I loosened the petrol filler cap, so there was no vacuum. Just under the throttle-body you can see the two fuel lines coming in, just give each one a little squeeze on the protrusions, pushing onto the lines slightly before pulling off, there might be a little fuel dribble at this point, and some fuel might drain out of the rail. Now there’s a little screw that holds a fixed clip, this keeps the two pipes in place, it looks like a cross-head screw, but it’s a small Torx, I think T25, it might be a bit filled-in with dirt. Get this undone before unbolting the injector rail. Un-bolt the fuel-rail, two M8 bolts using 10mm socket/spanner. Lift the fuel rail off and feed the two pipes through the manifold.

Look for the next post!!

Title: Re: Inlet Manifold Part 1
Post by PJDavis on Mar 30^th, 2013, 5:09pm

Part 2................. ;D 8)

I marked all the breather pipes and ancillaries by putting masking tape around them and numbering. Now I initially had problems removing the brake-servo vacuum, but you see in the three pictures that you need to push down on the lip the screwdriver is baring on to, and then pull up and out, you won’t remove this pipe by just pulling!

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3465_zps952c838d.jpg

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3466_zpsf2d41461.jpg

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3467_zps2e90ac46.jpg

I now went under the car and removed the bolt on the underside of the manifold. Not a very good picture, but I circled the bolt in red, you can also see the fuel lines arrowed green in the picture from underneath.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3460_zps25286aed.jpg

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3458_zps9f8ae0bf.jpg

Now just to remove the manifold. The bolts are M8 with 10mm socket/spanner heads, my bolts were all three along the top, and one just under the switches at the back of the thermostat housing. There are two nuts on studs, again M8 but the nuts are 13mm heads. The studs have a male Torx end, and need to be extracted using an E7 female Torx tool. All came out fairly easy, and the Two-Torx-Studs are double-ended. It still took a bit of jiggling to get the manifold out, eventually if looking at the manifold from the drivers-side of the engine compartment, you imagine pulling the manifold straight out from the head as far as you can and lifting the right side upwards to clear the alternator, putting it back in this way as well.

Replacement is easy enough, just reverse the procedure. I made sure the manifold was bolted up tight to the head before I went under the car and located the bottom bolt in the manifold, it was lined up perfectly. Might as well put in a new Thermostat, and you should really use new wee rubber gaskets between the manifold and head, especially the water-way. Might be an idea to run a tap through the threads of all the inserts if you’re putting the same inlet manifold back on.

http://i771.photobucket.com/albums/xx357/PJJDavis123/DSCF3472_zps43d92056.jpg

If admin want to change this or put it one post that would be great. If anyone else wants to add bits that I've missed that would be just fine as well.

Hope this helps someone.

Peter