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[geoffr70]

Hello, today I decided to do my drivers side exhaust manifold gasket and replace HBV. Everything going fine, but extremely awkward and limited space, especially two bolts holding coolant pipe on at back of block. Give me another ABS ECU to do anyday! My heat shield bolts (bar one), and manifold nuts came off easily. The problem is I've taken the nuts off the manifold to downpipe flange when I was under car, all nuts/studs are out of manifold, it moves freely, but I just can't get the manifold away from down pipe. I've managed to get the gasket out, and when I put my fingers there and wobble everything I can feel the gap getting bigger but it just won't budge. I can feel and see that the threads are still going between downpipe and manifold, but surely it can't be this that's holding it on as I said the gap gets bigger when wobbled? Also, I've got the manifold gasket out but this doesn't look like in bad nick so was it that actually blowing? I'm hoping after all this it'll be alot quiter, I've been on 9 hours!

[Marks DTM Calib]

Get under the car and place your right foot against the centre silencer and push it towards the rear of the car whilst pulling the front pipe down and off the manifold nuts.   

[Darth Loo-knee]

Did you remove the bolt each side that holds the cat up? There is a bracket that is fastened to the gearbox which goes to both CATS.
The cats should then drop down with some pulling.
 

[geoffr70]

Thanks both! Darth Loo-knee I  took the bolt out from the bracket off the gearbox so the pipe hangs down then tied it up so as not to strain it, there's still plenty slack for it to release from manifold though! 

Marks DTM Calibration I'll try what you suggested in the morning!

Thank you both!

[amba]

Would it not be better to undo the cat to middle box first then remove the entire cat.That way you have complete access to the manifold and then on reverse fit just replace the cat once meanifold and new gasket is in place.........or am I missing something from your problem.

[geoffr70]

Would it not be better to undo the cat to middle box first then remove the entire cat.That way you have complete access to the manifold and then on reverse fit just replace the cat once meanifold and new gasket is in place.........or am I missing something from your problem.

Urgh, I don't know! I'm tired and confused! I need to get the down pipe away from manifold. Nuts have been taken off downpipe flange, and all manifold nuts and studs are out. I just can't get downpipe away from manifold. I will do what MDTM suggested in the morning. It's my birthday tomorrow so I'm hoping I'll wake up and the birthday fairy will have done it for me! No, I'm being serious!

[amba]

Many happy returns for tomorrow and lest hope the manifold fairy has done his bit for you.

Reading your posts with interest as I have a similar problem with my nearside manifold but will be seeking the services of our resident mechanical magician when piggy bank is healthier as it all seems more than I can deal with.

I do wish you the best of luck..some say the drivers side is the better to do !!..I am encouraged that all the manifold studs came out without the much suggested snapping into the head.

Keep us informed of your progress please.

[Andy H]

The down pipes have spigots that slide into the manifolds. I'm guessing that carbon has built up on the spigots and is making it difficult to slide the manifolds off the spigots.

[geoffr70]

Thanks Andy H I thought there was something else holding it in, what's a spigot though? I know - I'm thick hahaha!

Amba06128, thanks for your kind words! I have heard drivers side is easier, although it doesn't feel like it, nothing a bit of shut eye won't sort! I was amazed how easily the they all came out. Heat shield ones were easy to access bar one (rear bottom next to steering box), so I had to use tin snips and butcher it. Manifold studs came out lovely with only 1 stud staying in block. Got new studs, nuts and all gaskets obviously! I had my stud extractors ready just in case.

I will endeavour to keep you informed. Someone was so kind as to write me a mini guide, it's in a post a few pages back, and I followed that. As good as what it was, and me being thick it wasn't straightforward by any means. So I'm going to take photo's tomorrow on reassembly and try to make some sort of idiots guide to point people in the right direction, who like me are just recently venturing beyond service items. If I can do it, anyone can. I think it's just being patient and methodical, but some bolts, like coolant hose at rear of the block were just so awkward to get I don't even want to think about putting them back in!

I would've loved to pay someone else to do this, but I've got more time than money right now, hence my battered hands!

[Andy H]

The exhaust pipe pokes through the flange by about 12mm on a pre-facelift (or 6mm on a facelift) this is the 'spigot' that slides into a recess in the manifold.

There are some pictures somewhere in the help section. If I can find them I will post a link.

[geoffr70]

Thanks again Andy H