Manifold Fitting!?!?!?!

[richardhammond]

I have Got one but theres no room to get it in to cut it off!!!

[Ben Lessani]

I took the two troublesome nuts off with a dremel - theres not masses of room - but its doable. Only took about 5 mins. Its such a tight space - its a real pita!

[richardhammond]

I could be easyer if i could get the down pipe off how does it come off there are massive clips on it that i tryed to prise off with screw driver and neary broke my finger it will not budge!! is there a tecnique?? i am getting FU**ED OFF with it now!! Please help!!

[Diluxe]

hmm if you look from underneath downpipe to manifold is 4 0r 6 17mm bolts, not sure what clips your trying to take off mate

[herbster]

hmm if you look from underneath downpipe to manifold is 4 0r 6 17mm bolts, not sure what clips your trying to take off mate

Sounds like you go the spring clamps on you downpipe, bummer, the edges of the 'C' sit in a slight groove, so just free one side at a time to remove, or if you know someone in a garage they will have access to the tool, sealey and draper both do one, you'll need it to fit it anyway unless you change your downpipe and manifold! 
good luck 

[richardhammond]

It is all coming off!! Should i just cut it with an angle grinder??

[OakeyDoak16v]

OFF! OFF! OFF! 

[Diamond Hell]

Using any sort of pry bar will normally remove the C-clamps.  You really shouldn't need to cut them.

If anyone needs to fit them at some point it is possible to use a fanny-stretcher like this:



Just be VERY careful when winding it open - I've use molegrips over each end to get it to that state.

When you've gingerly put the clip in place you only need to give it a tap and the bolt pops out.  Be careful though!

[richardhammond]

Me and my mate had one last go at prising it off with no succuses. So with my mate under the car with some goggles on! (brave i know) and me with angle grinder in hand he drected me where to cut and off it came!!!!!! But that was just the down pipe!! So on we went the round bolt was next on my HIT LIST!!! CUT and that was the end of the bolt!!!! But know theres still the problem of the two last bolts in between the inlet manifold and the top of the exhust!!!!!!!!!!!!!!!!!!!!!! What type of nut size are they or are they the ones which need an super long alen key if so where can i get one??

[Diamond Hell]

Your manifold-to-head studs should have 12mm peened brass nuts on them.  You will find it a lot easier to do the whole lot if you remove the inlet manifold.  I know it seems like more hassle, but it will make the overall job a lot easier and you'll be able to tighten things up properly.  I presume by the set up you've described you're dealing with a carb motor.

In order to undo all of the studs holding the inlet manifold on you'll need to get a very long 6mm allen key.  Alternatively you'll need a 1/4" drive socket, extension bar and socket to suit your bit - probably 8 or 10mm.  A mirror and a torch will help you find the offending bolts - they're right in there!

Make sure you replace the peened nuts with equivilent replacements (available from GSF), or they'll come loose again fairly soon.