hi all. these are all the info that I gathered over the time so if something can help ya...
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quick run down would be:
1.remove the flexi pipe from the system (manifold replaces the flexi pipe)
2. support the bottom of the engine with a hydraulich jack, but be careful as the sump is fragile, use a piece of wood or something to spread the weight, and just gently take the weight off.
3. remove the coolant tank from its position, no need to disconnect it just move it.
4. underneath the coolant tank is the engine mount, remove this
5. pull the engine towards the slam panel, and lower gently on the jack, this should allow you enough room to get the old manifold off
and basically just do the same but in reverse for putting the new manifold in, you will have to adjust the heatshielding and take the Lambda sensor out of its holder so it can reach, take the old manifold out from the top and put the new one in via the top
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by PumaSpeed:
Fitting tip :undo the lower gearbox stabilizer and the top cam chain side engine mount. this unit will slide in from the top once the engine is allowed to float. Remember to support the engine from underneath.
Fitting Tip-
1. Remove the original flexi.
2. Remove the lower gearbox stabilizer.
3. Remove the original manifold.
4. Support the engine front underneath (Beware the sump is fragile).
5. Remove the cam chain side engine mount and PS tank lid.
6. Pull the engine forward and down.
7. Expand the transmission tunnel heat shielding to allow for the 4 new headers.
8. Slide the manifold in from the top and bolt into place
9. Re-assemble the vehicle.
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Manifold bolts:
Two bolts on the heat shield at the top, remove them. Get under the car and look up, two bolts on each side. IIRC they are 8mm.
Push the heatshield down the lenght of the manifold from the top. At this point remove the flexi, standard or non standard.
There is 8 15or13mm nuts, would advise you to him them with a bit of wd40/duck oil etc. Should be able to undo them with a socket and/or a spanner. they are quite tight but should get them. If you looking down on the engine there are two nuts on the right hand side, i would recommend having a go at these from the bottom.
Moving the engine:
Remove the 8mm bolt from the header tank. Push in the clip that holds it in also and slide the header tank up. As per Lee's picture i just rested it on the rocker cover, you may have to squeeze a pipe to manouver it past the eniogne mount but it will go, be careful not to move it too much, the pipes are fragile if bent awkwardly.
Jack under the sump with a block of wood to help disperse the wegith of the engine. Under the gearbox stabliser on the bottom of the engine using 13mm socket, undo all four bolts to remove that, the engine may swing a bit but thats ok.
Apply a bit of pressure to the jack to lift the engine slighty, seriously though only a bit to take its weight at this point. Now go to your engine mount remove the three 15mm bolts holding it to the chassis, they should come out quite easily if you have the jack taking the weight. Once removed, jack the engione a bit more, just about a cm or so that you can see the mount is about a cm clear of its usual position,
You should be able to quite easily pull the enigne forward about a cm or 2 to get the engine forward, it will touch the slam planel/cross member on the front, this is ok. I was quite rough and it was fine. If it were to fall of the jack then worse case (if you remove the bit of the engine mount i suggested) would be it drops onto the chassis again, so just a quick jack up to take the weight can easily relocate it. (PS im referring to using a trolley jack which was able to move with the engine).
This should give the required room to drop the manifold out of the bottom and insert the new through the top, May be worth having a second set of hand to put the new one in, that way someone can pull on the engine to maximise space and the second can thread the mainfold in, dont be afaird to bend the scuttle panel slightly to get it in some gentle persuasion will do the trick.
My only other advice would be make sure your lambda sensor is lenghtened if required prior to fitting the new manifold as i made that mistake by mis-measuring it and had to extend and solder it whislt in the engine bay with no room.
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scuttle panel out makes it so easy, its untrue!
Basically, whip the wipers off, pull the little tabs out(like a L shape thing ) in both bottom corners of the windscreen, and then carefully prise the scuttle panel out of the black clip that is the length of the windscreen(you can only see it when you start prising the scuttle panel out).
With that removed, you need to remove the box that takes in air for the cabin fan(only 4 self tapper hex head screws).
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btw some of these are written by guys from various forums. I hope they don't mind putting this here.
let me(us) know of your progress please ;-).
cheers.
Edited by geronimo (16/10/12 06:05 AM)
Site Supporter
now you need to remove the plastic at the bottom of the windscreen (scuttle panel?) it's held in by various clips and screws can't tell you exactly as it's a long time since I've done one. Then you need to get someone to help you and pull the engine forwards towards the front of the car. This should then give you enough room to access the manifold bolts and remove the manifold from the engine bay. This probably doesn't help much would be much easier if I had some pics to go by. Hope it might help a little bit. Or in other words get a garage to do it far easier no swearing or effort involved! 
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