pkw2704 Posted November 19, 2021 Share Posted November 19, 2021 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? Link to comment Share on other sites More sharing options...
SM25T Posted November 19, 2021 Share Posted November 19, 2021 Do you mean you cant unstick it from the head, or you can't get it out of the engine bay ? Link to comment Share on other sites More sharing options...
Area Representative Geoff Brown Posted November 19, 2021 Area Representative Share Posted November 19, 2021 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. Link to comment Share on other sites More sharing options...
Leadership Team SLR No.77 Posted November 19, 2021 Leadership Team Share Posted November 19, 2021 From memory I think you'll either need to remove the studs from the head or the coolant rail ....Stu. Link to comment Share on other sites More sharing options...
Alastair B Posted November 19, 2021 Share Posted November 19, 2021 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. Link to comment Share on other sites More sharing options...
pkw2704 Posted November 19, 2021 Author Share Posted November 19, 2021 ok guys,update managed to release the manifold,took the lambda and battery off and it just came out,cant say I am lookingforward to trying to worm the 4 pipes in the same area ,any tips on that process? Link to comment Share on other sites More sharing options...
nic.day Posted November 19, 2021 Share Posted November 19, 2021 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. Link to comment Share on other sites More sharing options...
Wrightpayne Posted November 19, 2021 Share Posted November 19, 2021 You wait till you try removing the boot floor! Link to comment Share on other sites More sharing options...
pkw2704 Posted November 19, 2021 Author Share Posted November 19, 2021 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 Link to comment Share on other sites More sharing options...
Baggiebird Posted November 22, 2021 Share Posted November 22, 2021 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. Link to comment Share on other sites More sharing options...
Roger Ford Posted November 22, 2021 Share Posted November 22, 2021 Remove the engine mounts and jack the engine up a couple of inches. That should give you enough clearance. Link to comment Share on other sites More sharing options...
pkw2704 Posted November 22, 2021 Author Share Posted November 22, 2021 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!!! Link to comment Share on other sites More sharing options...
Area Representative Geoff Brown Posted November 24, 2021 Area Representative Share Posted November 24, 2021 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. Link to comment Share on other sites More sharing options...
pkw2704 Posted November 24, 2021 Author Share Posted November 24, 2021 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 Link to comment Share on other sites More sharing options...
Area Representative Nick Bassett Posted November 25, 2021 Area Representative Share Posted November 25, 2021 Looking good! Link to comment Share on other sites More sharing options...
Seabea23 Posted November 25, 2021 Share Posted November 25, 2021 Very nice, who made the system? Link to comment Share on other sites More sharing options...
pkw2704 Posted November 25, 2021 Author Share Posted November 25, 2021 its the caterham SLR system Link to comment Share on other sites More sharing options...
pkw2704 Posted December 1, 2021 Author Share Posted December 1, 2021 all fitted and hopefully all ok. Link to comment Share on other sites More sharing options...
Seabea23 Posted December 2, 2021 Share Posted December 2, 2021 Looks very neat, have you started the car up with it on yet to check the joint sealing? Link to comment Share on other sites More sharing options...
pkw2704 Posted December 3, 2021 Author Share Posted December 3, 2021 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 Link to comment Share on other sites More sharing options...
tweeky Posted December 7, 2021 Share Posted December 7, 2021 I thought lagging on the K series was a no no keeping the heat in the cyl head rather than letting it out . Link to comment Share on other sites More sharing options...
Leadership Team SLR No.77 Posted December 7, 2021 Leadership Team Share Posted December 7, 2021 That's my opinion Tweeky, but opinions are akin to belly buttons, everyone has one and everyone's is different!Stu. Link to comment Share on other sites More sharing options...
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