tom_simes
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Hi guys, to fit a new manifold and decat pipe to a Corsa 1.6, what parts do I need?
Obviously:
manifold gasket
cat to manifold gaskets
need new flexi joint bolts as mine are badly rusted
shouldn't need new u-clamp, only fitted a few months back to hold cat to rest of system.
Anything else? New studs and nuts for manifold?
Does the oil filter need removing?
I am looking to keep the SAI by the way, is anything special needed with a Janspeed 4-2-1 to keep it working?
cheers 
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Dean_W
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Registered: 13th Dec 05
Location: Downham Market, Norfolk
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SAI just goes back on. Hole is there and also the thread for the nut to hold the mushroom on the manifold.
What de-cat is it?
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tom_simes
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Janspeed with a silencer, and a flange to match the manifold.
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Dean_W
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Location: Downham Market, Norfolk
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Right. You'll need the above plus a hacksaw or grinder.
And either a pipe expander or a joining piece to join the de-cat to the middle section as the janspeed ones don't go to the backbox.
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tom_simes
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So the Janspeed ones are a different bore to the standard cat? As I have a cat back stainless system on there anyway, won't that match direct to the Janspeed de-cat?
and the hacksaw - to split the old join between the cat and centre pipe?
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Dean_W
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Registered: 13th Dec 05
Location: Downham Market, Norfolk
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Sorry Tom, should have made it a bit clearer.
The de-cat is the same bore as standard. Cat back should go straight on it.
Hacksaw, yes to split it.
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tom_simes
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Cheers Dean
People recommend getting a stud and nut kit as well then?
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Scotty C
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Registered: 6th Nov 05
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I would recommend it, yes, but you don't NEED it, I didn't use them.
[Edited on 21-01-2008 by Monster]
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Robin
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Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
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I didn't use one in fitting mine, I used the old ones, even the ones which came out of the head 
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tom_simes
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How do the studs remove from the head?
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Superlite Ltd.
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Registered: 9th Jan 07
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I couldn't get my manifold past the filter so i did an oil change while i was there.
that was on a c16xe
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Robin
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quote:
Originally posted by tom_simes
How do the studs remove from the head?
They're just a threaded bit of metal, like a bolt with no head, so they sometimes just unscrew.
The Janspeed flange is the same thickness as the standard one though, so if that happens, they'll still hold it in properly.
I agree with Ed about the oil change, I couldn't get the manifold past the filter with the rad in place.
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tom_simes
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I also could do with changing my rocker cover gasket as well, got a bit leaking from just below the filler cap onto the exhaust manifold so may do that the same time.
Fair bit of maintainence that weekend then, whenever my decat arrives!
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Robin
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I wouldn't do the rocker cover gasket if it's only a little leak, it's quite unlikely you'll solve the problem anyway, as they're crap, even when replaced
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tom_simes
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Ok, I will just give the cover and the block a good clean while the exhaust manifold is off then.
Cheers guys, any other tips or problems you came about when doing yours?
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Superlite Ltd.
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Registered: 9th Jan 07
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Rocker cover gaskets on smallblock XE engines piss me off!
I used LOADS of hermitite red in the end and that stopped it leaking 
[Edited on 21-01-2008 by Superlite Ltd.]
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fillmecca
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Registered: 16th Jun 07
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quote:
Originally posted by Dean_W
SAI just goes back on. Hole is there and also the thread for the nut to hold the mushroom on the manifold.
What de-cat is it?
I have just bought a 4-2-1 exhaust manifold. . . .
And you just remove the whole SAI 
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tom_simes
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Which 4-2-1 did you buy?
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Scotty C
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Registered: 6th Nov 05
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quote:
Originally posted by tom_simes
Which 4-2-1 did you buy?
You wont be able to put the SAI back on your manifold Tom, as it's been blocked off.
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Robin
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If he's got a Janspeed manifold, there's a hole.
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tom_simes
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No I don't Robin.
Its Scotts old manifold 
How does the SAI attach to the manifold then? or how do I go about removing it, without the EML coming on?
Edit: I mean, how is it meant to attach the manifold, before it was blocked off? Just the stud that Dean spoke about, or a small threaded connector or what?
[Edited on 21-01-2008 by tom_simes]
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tom_simes
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Can the connection be seen in either of these pictures?
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Robin
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I see, it has been blocked up there, yes.
Your best bet is to remove the bit on the manifold, then fit the new manifold, start the car, check for EML.
Then, remove the SAI pump, start the car, check for EML.
I can't remember what I had to do, but I think I needed to leave something plugged in, but I can't remember as it's nearly 3 years ago 
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tom_simes
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Is it the bit between cylinder 2 and 3, where it looks as though it has been welded up?
What actually should be there, just a threaded hole or....?
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Robin
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It is that bit, yeah.
There should just be a plain hole, about 13mm round (from memory), with another, smaller hole offset to one side above it, which takes a threaded torx bolt.
When you take the SAI off the standard one, you'll see the setup which would be on the new one.
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