Piper S2 4-2-1 Manifold Fitting - Revision history

Steve S2: /* Method */

2007-10-02T10:12:20Z

Method

← Older revision		Revision as of 10:12, 2 October 2007
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	[[Image:EngineMountW.jpg\|thumb\|Access to the engine mounting bolts]]		[[Image:EngineMountW.jpg\|thumb\|Access to the engine mounting bolts]]
	11. Remove two bolts holding engine mount to chassis - accessed via the offside rear wheel space.		11. Remove two bolts holding engine mount to chassis - accessed via the offside rear wheel space. These are the bolts that sit fore and aft of the engine mount and attach vertically down into the chassis longeron. Note that the bolts screw into some hard-to-access nuts inside the longeron extrusion. The nut to the fore of the engine mount is reasonably easy to access, whilst the aft one is more of a challenge and is best done by an assistant accessing it with a spanner via the car's boot. You'll need to use a spanner (open end) to hold the aft nut in place whilst undoing the associated bolt with a socket. For the bolt to the fore of the mount, you need to hold the bolt in place with a socket whilst undoing the nut underneath the longeron. Accessing the bolt to the fore of the engine mount will require a socket, a universal joint and a short extension bar.

	12. Remove the downpipe		12. Remove the downpipe

Steve S2: /* Method */

2007-10-02T09:56:48Z

Method

← Older revision		Revision as of 09:56, 2 October 2007
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	21. Looking from the rear of the car, slide the manifold in with it rotated 90 degrees anticlockwise		21. Looking from the rear of the car, slide the manifold in with it rotated 90 degrees anticlockwise
	offer the manifold up whilst jiggling the engine and pulling the manifold from above. Watch for the brake cable which runs exactly in the most inconvenient position. At times this task appears impossible. Just how can the manifold fit. Watch out for trapped fingers. Keep jiggling the engine block and rattling the manifold. Eventually it does pop through the impossible gap and into position.		offer the manifold up whilst jiggling the engine and pulling the manifold from above. Watch for the brake cable which runs exactly in the most inconvenient position. At times this task appears impossible. Just how can the manifold fit. Watch out for trapped fingers. Keep jiggling the engine block and rattling the manifold. Eventually it does pop through the impossible gap and into position. To re-iterate: it helps massively if you can have someone pulling the manifold upwards from above the engine bay at the same time as the person feeding the manifold under the engine. Brute force and ignorance are required, as the alternator heat-sheild mounting bracket on the manifold will foul against the transverse chassis rail at the base of the engine bay.

	[[Image:HoldingManifoldInSituW.jpg\|thumb\|Keep manifold steady as it is being bolted to the head]]		[[Image:HoldingManifoldInSituW.jpg\|thumb\|Keep manifold steady as it is being bolted to the head]]

Steve S2: /* Credits */

2007-10-02T09:49:58Z

Credits

← Older revision		Revision as of 09:49, 2 October 2007
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	== Credits ==		== Credits ==
	Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold star to Steve S2 for travelling 200 miles to the grim north and then ruining his legs, back, arms and shoulders during the 11 hour fitting marathon.		Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold star to Steve S2 for travelling 200 miles to the grim north, not forgetting to bring his jack, axle stands and ready-cut alternator heat shield and then ruining his legs, back, arms and shoulders during the 11 hour fitting marathon.

	[[Category:Exhaust]]		[[Category:Exhaust]]
	[[Category:Lotus Elise]]		[[Category:Lotus Elise]]
	[[Category:S2]]		[[Category:S2]]

Steve S2: /* Credits */

2007-10-02T09:48:41Z

Credits

← Older revision		Revision as of 09:48, 2 October 2007
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	== Credits ==		== Credits ==
	Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold star to Steve S2 for ruining his legs, back, arms and shoulders during the fitting ~~process~~.		Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold star to Steve S2 for travelling 200 miles to the grim north and then ruining his legs, back, arms and shoulders during the 11 hour fitting marathon.

	[[Category:Exhaust]]		[[Category:Exhaust]]
	[[Category:Lotus Elise]]		[[Category:Lotus Elise]]
	[[Category:S2]]		[[Category:S2]]

AndrewF at 16:22, 1 October 2007

2007-10-01T16:22:40Z

← Older revision		Revision as of 16:22, 1 October 2007
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	== Credits ==		== Credits ==
	Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold ~~start~~ to Steve S2 for ruining his legs, back, arms and shoulders during the fitting process.		Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold star to Steve S2 for ruining his legs, back, arms and shoulders during the fitting process.

	[[Category:Exhaust]]		[[Category:Exhaust]]
	[[Category:Lotus Elise]]		[[Category:Lotus Elise]]
	[[Category:S2]]		[[Category:S2]]

AndrewF at 16:22, 1 October 2007

2007-10-01T16:22:19Z

← Older revision		Revision as of 16:22, 1 October 2007
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	== Credits ==		== Credits ==
	Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences.		Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences. Special gold start to Steve S2 for ruining his legs, back, arms and shoulders during the fitting process.

	[[Category:Exhaust]]		[[Category:Exhaust]]
	[[Category:Lotus Elise]]		[[Category:Lotus Elise]]
	[[Category:S2]]		[[Category:S2]]

AndrewF at 08:03, 30 September 2007

2007-09-30T08:03:26Z

← Older revision		Revision as of 08:03, 30 September 2007
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	6. Time for first cup of tea and bacon sandwiches		6. Time for first cup of tea and bacon sandwiches

	[[Image:UndertrayHeatshieldAndORWheelW.jpg\|thumb\|Tray, heatshield, OR Wheel ~~(step 4)~~]]		[[Image:UndertrayHeatshieldAndORWheelW.jpg\|thumb\|Tray, heatshield, OR Wheel]]
	7. Remove manifold heat shield - three bolts.		7. Remove manifold heat shield - three bolts.

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	9. Crack off and put on loosely the bolts / nuts holding the downpipe to the cat and the cat to the exhaust. We had a major issue with one of the cat-exhaust bolts and had to chisel it off.		9. Crack off and put on loosely the bolts / nuts holding the downpipe to the cat and the cat to the exhaust. We had a major issue with one of the cat-exhaust bolts and had to chisel it off.

			[[Image:BackBoxAndCatSupportW.jpg\|thumb\|Stands, jack, and plastic bucket support!]]
	10. Remove CAT if possible. We left it in situ with the attached lambda sensor. Balanced on a makeshift bucket + toolbox platform. We did remove the back box though to provide more working space.		10. Remove CAT if possible. We left it in situ with the attached lambda sensor. Balanced on a makeshift bucket + toolbox platform. We did remove the back box though to provide more working space.

			[[Image:EngineMountW.jpg\|thumb\|Access to the engine mounting bolts]]
	11. Remove two bolts holding engine mount to chassis - accessed via the offside rear wheel space.		11. Remove two bolts holding engine mount to chassis - accessed via the offside rear wheel space.

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	16. Unbolt the manifold from the head		16. Unbolt the manifold from the head

			[[Image:OldManifoldAlmostOutW.jpg\|thumb\|Unbolted and almost out]]
	17. Remove manifold in two pieces through top and bottom of engine bay.		17. Remove manifold in two pieces through top and bottom of engine bay.

	18. Soak manifold lambda sensor in Plusgas		18. Soak manifold lambda sensor in Plusgas

			[[Image:AlternatorHeatshieldW.jpg\|thumb\|Alternator heat shield, to left of alternator]]
	19. Take off alternator heat shield. This took an absolute age. Be careful not to round off the bolts. Small spanners and a gentle bit of persuasion with a lump hammer will get you there eventually, along with lots of Plusgas.		19. Take off alternator heat shield. This took an absolute age. Be careful not to round off the bolts. Small spanners and a gentle bit of persuasion with a lump hammer will get you there eventually, along with lots of Plusgas.

	20. Oil filter off, catching 95% of the oil! Spend time mopping up the spillage until you have a clean worksurface once more.		20. Oil filter off, catching 95% of the oil! Spend time mopping up the spillage until you have a clean worksurface once more.

			[[Image:OldAndNewW.jpg\|thumb\|Compare old 'pig iron' mess, with sleek new manifold]]
	5hrs 30mins to this point. We now have everything off, its time to start to reconstruct with the new manifold. But more sandwiches and tea first...		5hrs 30mins to this point. We now have everything off, its time to start to reconstruct with the new manifold. But more sandwiches and tea first...

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	offer the manifold up whilst jiggling the engine and pulling the manifold from above. Watch for the brake cable which runs exactly in the most inconvenient position. At times this task appears impossible. Just how can the manifold fit. Watch out for trapped fingers. Keep jiggling the engine block and rattling the manifold. Eventually it does pop through the impossible gap and into position.		offer the manifold up whilst jiggling the engine and pulling the manifold from above. Watch for the brake cable which runs exactly in the most inconvenient position. At times this task appears impossible. Just how can the manifold fit. Watch out for trapped fingers. Keep jiggling the engine block and rattling the manifold. Eventually it does pop through the impossible gap and into position.

			[[Image:HoldingManifoldInSituW.jpg\|thumb\|Keep manifold steady as it is being bolted to the head]]
	22. Fit manifold to head using the new gasket - with the "half hole end" fitting next to the water outlet from the head. Remember to use two washers between in each nut and the new manifold's flange (new flange is perhaps 5mm thinner than old flange). Be extremely careful not to cross thread the head bolts!		22. Fit manifold to head using the new gasket - with the "half hole end" fitting next to the water outlet from the head. Remember to use two washers between in each nut and the new manifold's flange (new flange is perhaps 5mm thinner than old flange). Be extremely careful not to cross thread the head bolts!

			[[Image:NewManifoldInW.jpg\|thumb\|What 'success' looks like :-)]]
	23. Alternator heat shield will need clipping with tin snips. Perhaps 5-6cm cut from the plate in order to accommodate the new manifold. I reused the one from Steve S2's car as it was a cast off from his Honda upgrade. I've didn't take a photo of the original and trimmed heatshields for reference. Sorry.		23. Alternator heat shield will need clipping with tin snips. Perhaps 5-6cm cut from the plate in order to accommodate the new manifold. I reused the one from Steve S2's car as it was a cast off from his Honda upgrade. I've didn't take a photo of the original and trimmed heatshields for reference. Sorry.

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	26. Refit engine mount bolts		26. Refit engine mount bolts

			[[Image:EngineBracketAlignmentNewAndOldW.jpg\|thumb\|Use the old to set the new length correctly]]
	27. Set the new adjustable engine steady bar to same length as the standard steady bar		27. Set the new adjustable engine steady bar to same length as the standard steady bar

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	35. Line up the undertray to guesstimate where extra sheet metal will have to be removed (approx 10cm x 15cm piece on the off-side rear of the existing hole.		35. Line up the undertray to guesstimate where extra sheet metal will have to be removed (approx 10cm x 15cm piece on the off-side rear of the existing hole.

	36. ~~Snip out~~ the sheet metal.		[[Image:CuttingUndertrayW.jpg\|thumb\|Angle grinder on the undertray, showing rough pattern to cut.]]
			36. Use and angle grinder and snips to cut the sheet metal.

	37. Take the car for a spin. Listening for anything 'out of the ordinary'. I went for a 15 minute blast, getting up to 6000rpm - all OK.		37. Take the car for a spin. Listening for anything 'out of the ordinary'. I went for a 15 minute blast, getting up to 6000rpm - all OK.
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	== Conclusion ==		== Conclusion ==
	A valuable upgrade, definitely recommended for the price. Next step is to tie this into a cam change to extend the characteristics across the full range. For more info on just how a change in manifold design can make such a difference, follow [http://forums.seloc.org/viewthread.php?tid=136395] this link.		A valuable upgrade, definitely recommended for the price. Next step is to tie this into a cam change to extend the characteristics across the full range. For more info on just how a change in manifold design can make such a difference, follow [http://forums.seloc.org/viewthread.php?tid=136395] this link.

	~~== Photos ==~~
	~~A selection of pictures of our day's activities can be found at [http://www.facebook.com/album.php?aid=15371&l=6db72&id=535283125] this link.~~

	== Credits ==		== Credits ==

AndrewF at 07:52, 30 September 2007

2007-09-30T07:52:59Z

← Older revision		Revision as of 07:52, 30 September 2007
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	3. Remove offside rear wheel		3. Remove offside rear wheel

			[[Image:WorkingConditionsW.jpg\|thumb\|Working Conditions - N.B. Liner pulled back (step 4)]]
	4. Remove offside rear wheel arch liner. We had a issue with the rearmost lowest screw and so bent the flexible liner out of the way to access the engine mount bolts.		4. Remove offside rear wheel arch liner. We had a issue with the rearmost lowest screw and so bent the flexible liner out of the way to access the engine mount bolts.

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	6. Time for first cup of tea and bacon sandwiches		6. Time for first cup of tea and bacon sandwiches

			[[Image:UndertrayHeatshieldAndORWheelW.jpg\|thumb\|Tray, heatshield, OR Wheel (step 4)]]
	7. Remove manifold heat shield - three bolts.		7. Remove manifold heat shield - three bolts.

AndrewF at 17:13, 29 September 2007

2007-09-29T17:13:54Z

← Older revision		Revision as of 17:13, 29 September 2007
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	== Credits ==		== Credits ==
	Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences.		Credit to SteveB, Steve S2 and BrianDrought who provided this comprehensive activity list based their own experiences.

			[[Category:Exhaust]]
			[[Category:Lotus Elise]]
			[[Category:S2]]

AndrewF: S2 4-2-1 Manifold Fitting moved to Piper S2 4-2-1 Manifold Fitting

2007-09-29T16:37:45Z

S2 4-2-1 Manifold Fitting moved to Piper S2 4-2-1 Manifold Fitting

← Older revision	Revision as of 16:37, 29 September 2007
(No difference)