Help...K series manifold removal

[pkw2704]

ok,so in the process of fitting a 4-2-1 system to my k series car(2005)  dropped the old silencer off no problem,and all the manifold bolts came out fine.The issue now is i cant seem to get the old 4-1 manifold out,undone the engine mounts to see it that helped but no,anyone got any tips ,or can tell me where i am going wrong?

[SM25T]

Do you mean you cant unstick it from the head, or you can't get it out of the engine bay ?

[Geoff Brown]

Removing the 4-1 manifold is the Rubiks Cube dilemma with a K Srs.

When I changed a 4-1 many, many years ago not only did I disconnect the near side engine mount & jack the engine up a little on that side but I also extracted the studs using the two nut method.

[SLR No.77]

From memory I think you'll either need to remove the studs from the head or the coolant rail ....

Stu.

[Alastair B]

Dave Andrews shortened my studs as a courtesy when doing some head work for a future exhaust replacement. Assuming you remove the studs, shorten them before replacing.

[pkw2704]

ok guys,update managed to release the manifold,took the lambda and battery off and it just came out,cant say I am looking

forward to trying to worm the 4 pipes in the same area ,any tips on that process?

[nic.day]

This is the fun and games I looking forward to next week - I managed to get it all off. Getting all the bolts off was fun to say the least and managed to get each primary out - just cleaning everything up ready to re wrap the primaries. Can has been re packed and ready.

So a bit of polishing over the weekend, wrapping and then wish me luck putting it all back together.  

[Wrightpayne]

You wait till you try removing the boot floor!

[pkw2704]

Keep us posted,I have notice a chassis bar that goes across the top of the manifold area,some folk have removable ones which i would presume will make life easier

[Baggiebird]

You can also, as an alternative, take the n/s engine mount bolt out and gently raise the engine (trolley jack and wood packing) to achieve enough clearance.

[Roger Ford]

Remove the engine mounts and jack the engine up a couple of inches. That should give you enough clearance.

[pkw2704]

So update time,the old manifold came out once the engine lifted slightly ,and battery and lambda removed,still a pain in the ass though.

Cutting the hole in the side ,very stressful and time consuming,checking and re-checking before trimming.At the stage where its starting to take shape and light at the end of the tunnel,pics so far ,but i need the just trim one primary so all off again!!!

[Geoff Brown]

Good job! 

Don't forget to manufacture a heat shield for the starter motor or the dreaded 'K click' will eventually come to haunt you.

[pkw2704]

I think its got some form of reflective cover on already ,its the alternator that concerns me,although i have some manifold lagging to help with that 

[Nick Bassett]

Looking good! 

[Seabea23]

Very nice, who made the system?

 

[pkw2704]

its the  caterham SLR system 

[pkw2704]

all fitted and hopefully all ok.

[Seabea23]

Looks very neat, have you started the car up with it on yet to check the joint sealing?

[pkw2704]

not yet thats today job,although i did use a hi temp sealer on the joints and manifold to head ,so I hope this cures any leaks

[tweeky]

I thought lagging on the K series was a no no keeping the heat in the cyl head rather than letting it out .

[SLR No.77]

That's my opinion Tweeky, but opinions are akin to belly buttons, everyone has one and everyone's is different!

Stu.