DeanF

iTrader: (1)

This was Fitted (MY98)
http://images.fotopic.net/?iid=ymgol...480&quality=70
A Nice New Shiny Blue Silicone Inlet Pipe

May i just say !! What an absolute Barsteward to Fit !! Sorry Silent Running but i did not adhere to your warnings !!

Started at 6Pm & finished at 12.30 Am

This is what came out
http://images.fotopic.net/?iid=ymgol...480&quality=70
The original was split & was running around with a Samco Silicone There There There Plaster !!
I did not remove the Inlet manifold But did as below.
Remove Intercooler
Remove breather Hoses
Remove Turbo Coolant Hose
Slacken Alternator
Remove power steering belt
Remove Power steering Pump assembly (3 Bolts, 2 @ front, 1 on the Block)
Rotate the Hole pump assembly to the left & secure with some string in the inner wing area
Remove Maf flexible hose & breather pipe underneath it
Now time to be brutal
Using a saw as below
http://www.altecweb.com/images/large/83135_33.jpg
Saw off the Breather tails that are the turbo side of the inlet manifold .
Not forgetting to block off your turbo intake to stop all the crap falling in
Once the tails are removed he inlet pipe should come out with ease.
Time for more brutalness
On the fuel line & carbon canister fuel vapour pipes under the inlet manifold there are 3 brackets & a lug on the inlet manifold which they clamp to.
there is no way on Gods earth the new silicone inlet pipe will go in with these in place.
Chop all 3 mild steel brackets & fille the rough edges off. Then also chop the lug off the inlet manifold & file down again.
Once done, to stop the pipes moving & keep secure , I used good old Zip ties..

To get the new silicone inlet pipe in , I had to remove the hose tail inserts
As you can see in the below picture
http://www.flat4online.co.uk/catalog...gc89698bti.jpg
these were then secured back in place afterwards with Jubilee Clips
Now assume the Birth Position, Inserth the Inlet Pipe & Push until you go purple, You will have to pull also with your other hand from the Turbo Side, Eventually when you have burst a Blood Vessel, It will go in.
Resassemble in reverse Etc.
Phew.
http://images.fotopic.net/?iid=ymgol...480&quality=70

Wonder how long it would of taken to remove the inlet manifold

Im just waiting for all the smoke to subside now from the coolant that ran around the turbo housing, Looks like it's on fire !!!
Cheers

Dean

cookstar

iTrader: (6)

I paid someone to do mine

Jay m A

iTrader: (2)

You know you're going to fit manifold spacers next week, don't you?

DeanF

iTrader: (1)

I was thinking that when the clock nudged past midnight !!

Dean

OcTag3n

iTrader: (4)

I recently did this on mine but I took the manifold off to recoat it as the red paint was flaking off a bit.

Got a bit nervous though when my engine looked liked this....



Would I remember where all the different bits went

Wasn't too hard to do & I'm no mechanic by any respects. At least now theres proof it can be done without taking the manifold off.

Well done

DeanF

iTrader: (1)

Looks like there has been a small but contained explosion !!
Good job there id say too

Cheers
Dean

p1mark

I'm no mechanic, but have done quite a few manifold exchanges now (i.e swap all the rails/injectors/inlet pipe/electrics onto a newly painted manifold then built it on the car) and it takes 4 to 5 hours.

Don't have to chop bits or smash pipes either!

DeanF

iTrader: (1)

There was no smashing, Just precise controlled removal, The items that were removed were not critical Items & would not cause any problem. If they had of done the manifold would of been taken off. I just did not fancy the potential issues that could be caused by removing it !!
Most people do not want to attempt items like the manifold removal, I looked at it & thought it would be possible to fit the inlet pipe without removing the manifold, Thats anopther reason i went that route, To see if it was possible & much simplier for the Diy -er !!
& i did stop for Tea so that shortens it by 45 Mins !!

Dean

silent running

LOL if it's any consolation Dean, I did get halfway through the hard method before realising that it was going to be a nightmare, and resorted to taking the manifold off. Still you live and learn, eh?

TBH now I've done the IM removal once, it wouldn't particularly worry me having to do it again, just set aside a day and the job's a good'un. But congratulations for fitting your pipe with the IM in situ. That's definitely a '6 spanner' job.

911

It is a real bitch of a job. I took the manifold off in a fit of frustration and did the parallel fuel rail mod too.
Wish i had painted it but was too p!ssed-off at the time.

p1mark

Fair play Dean

i look at it the other way, The assembly was designed to be fitted with the inlet pipe attached to the manifold. That's how it's done in the factory (although with the engine out admittedly) so thats how i will do it.

911

Best idea.

DeanF

iTrader: (1)

These Production line fitters have no thoughts for the humble human being !!
I wonder how different a car would look (& Cost) if it was assembled for ease of maintenance ?
Imagine the bliss of everything being accesible & easy to work on

Anyway enough dreaming , back to the cold heart of reality !!


Dean

911

But:
Impreza's don't go wrong, so nobody needs to take them apart (easily).
Design for comprehensive 'mechanicing' = lots of money.

p1mark

On the contrary, every automotive manufacturer has ease of assembly very high on the hit list. Mainly for assembly operatives but also for service personnel.

It is obviously lower on the list than packaging, size and lighteness though, hence why cars are such a relative barsteward to work on compared to 20 years ago

timmccr

How come you changed? Any difference in turbo response? I've often pondered this mod, just coz I like coloured silicone products (that probably sounds so wrong!), but the time/effort needed kind of puts me off.

If it's worth it I'll pay some other poor sucker to do it for me!

The Hoff

iTrader: (5)

For those who whipped off the inlet manifold, did you resuse the gasket or replace it?

p1mark

Always replace. Its not a job you want to do twice.

DeanF

iTrader: (1)

I changed as the Original one had split (Quite Common), I have not had much of a chance to test it, But it definately feels smoother & pulls stronger, Thing is though, It was split beforehand, Although it did have a Samco bandage on
So i may just be experienceing the feeling of near to normalness !!
If that makes sense !!

Dean

unfeasablylargegonads

iTrader: (3)

I did mine on my classic, it had split at the bottom. It was hard to find the problem (I removed the intercooler + every other induction releated pipe/sensor, dump valve etc several times trying to find why I could hear a slight hissing noise on WOT).

I took the manifold off and used new gaskets, I am not a mechanic either but found it ok to do.

OcTag3n

iTrader: (4)

I also replaced the gaskets but I painted the manifold with a paint that I think is too shiney compared to the standard finish.

Being the perfectionist that I am, I have bought a can of VHT wrinkle coat paint that was recommended on here by a few & I think API use it to recoat their manifolds.

So now I'm gonna take it all to bits again, just to re-paint the manifold!

Looking forward to it this time though cause I know what I'm doing.

Think I'll wait till the weather gets a bit warmer first then its shirt off in the sun, mates round with some beers & the missus cooking on the barbie.... I love the summer

silent running

The consensus is: don't change your inlet pipe unless you have to because the old one's split. It does make a difference I think - I've maxed out my MAF sensor now I've got a silicone pipe in - but not worth doing for 'fun'.