Changing the manifold gasket (from old site)

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contributed by Mark Branston
Manifold gasket leaking? Here's what to do...


Here's my guide to changing the manifold gasket.

1) Make sure that the manifold gasket is actually leaking, and not the springy downpipe connection. (As I discovered after doing this procedure at least twice!)

2) If you do decide to change the gasket, liberally spray all nuts with WD40.

3) Leaving all oil and water hoses attached, remove the 4 bolts from the turbo to the exhaust manifold, then remove the two bolts at the turbo elbow attached to the collar. (See figures 1 and 2)

4) Remove all water/turbo/fuel pipes, accelerator cable and choke cable from the carburettor. Then remove the carburettor by taking off the two nuts attaching it to the inlet manifold. (See figure 3)

5) Slide out the plate and hose holders that are attached by two bolts to the inlet manifold. You can then see some of the manifold nuts. (See figure 4)

6) Undo all the manifold nuts you can see, but leave one of the inlet manifold nuts loosely attached (as you won't want it to just drop off on your head)

7) Jack the driver's side front wheel up and crawl underneath and position your head under the inlet/exhaust manifold, so that you can see this view. (See figure 5)

8) Undo all the nuts you can see, by reaching around the subframe (you should be able to reach it), then move your head further towards the drivers side wheel, you should be able to just about see and reach the remaining nut on the inlet manifold. Remove remaining inlet manifold nut from the top and take off the manifold. (See figure 6)

9) Remove all remaining nuts attaching the exhaust manifold to the head. Then remove the manifold.

10) Replace the manifold gasket with the metal side facing the head.

11) Refitting is the reverse of removal!


Figures 1 to 6 are on right.
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