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Equinox

From hero to zero. The story of replacing your manifolds.

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What socket are you using to remove the oxygen sensors?  I picked up an offset pair from Screwfix recently and the 1/2" one was a bloody life saver (it paired with my 30cm breaker bar) when all else failed.  The 1m bar wouldn't fit. :D

 

This thread has given me both joy and pain.  I cancelled an order for FVD manifolds about this time last year - pretty glad that I did having read this.  Keep us updated on your progress! 

 

Are these the Topgear manifolds or something else?

 

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Brave man!  Well done for taking this on.  What a nightmare it must be if they all snap and you can't secure the jig!

 

Keep us posted.

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Wow excellent work.

 

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Often wondered what is really involved to do this, now I know I won't be undertaking it myself ! 

 

Great effort and thanks for posting it up. 

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worse to come.....you will need a better story to sell to your partner on the added repair costs lol

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On 07/05/2019 at 02:02, Aaron said:

What socket are you using to remove the oxygen sensors?  I picked up an offset pair from Screwfix recently and the 1/2" one was a bloody life saver (it paired with my 30cm breaker bar) when all else failed.  The 1m bar wouldn't fit. :D

 

This thread has given me both joy and pain.  I cancelled an order for FVD manifolds about this time last year - pretty glad that I did having read this.  Keep us updated on your progress! 

 

Are these the Topgear manifolds or something else?

 

Yeh they are too gear manifolds. Look to be pretty good quality tbh. Currently can't fault them. 

 

Just had a spanner and was hanging off it while the manifold was in a bench vice. Wasn't going anywhere so have just ordered some new ones. 

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Next piece of the puzzle has arrived. 

 

IMG_20190509_000521.jpg.7fdb0fe9a79204c72cb44035234a41cb.jpg

 

Just gotta wait for these drill bits to arrive and I can crack on and get it all finished. 

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On 06/05/2019 at 23:38, Equinox said:

This story begins with a dream. A dream to have loud noises, more hp and shiney new car parts. Some of this came true but let's take you through the story that is.

 

Replacing stock manifolds with high flow cats (sold to the misses because the gasket on one side started leaking so obviously both might as well be done and an upgrade should happen at the same time to save money....) 

 

IMG_20190505_120431.jpg.e73661aeb56329fd72595e265465555e.jpg

 

As Google will tell you and from what you can gather when a indie specialist wants nearly 1k to do it. Replacing the manifolds on these is a bit of a pitta. Mainly due to the inevitable blackboard scratching sounds that is the snapping of the manifold bolts into the block on removal. 

 

So knowing the issues and that it's almost definitely going to happen after looking at the brown crusty goodness that was currently holding them in place. I went ahead an ordered a Stomski racing drilling jig from Porsche Shop UK. 

 

Now it is an expensive bit of kit for what it is. However if I didn't have it I wouldn't be writing this post as I'd have already been signed into the local institute not knowing what way was up anymore. 

 

So the kit is very comprehensive. Comes with everything you will need to do the job of drilling out the snapped studs including a tap to chase any holes you don't get the old thread out from. Everything is very high quality and very well presented. 

 

IMG_20190501_180012.jpg.3e3e08076e23a236f2a704d194ff4dc5.jpg

 

So onto the job. Removing the rear section of the exhaust was the first job. And even though I'd had the fixings replaced when I had the 2nd cats deleted these were still heavily corroded and wouldn't budge. Managed to get a couple off but some took brute force and some help from Mr angle and Mrs grinder to cut them loose. 

 

IMG_20190505_120501.jpg.dffc20364c41effd50c3729d7423e0d1.jpg

 

Next after a day spent dealing with that we move onto the money shot. All manifold bolts had been sprayed with PB Blaster over the past month and just before starting had been left overnight drenched in the stuff. Pretty much bathed in it myself by the end of this. 

 

So onto the drivers side. And amazingly 1st....2nd....3rd....4th....5th and..... Ahhh dam it 6th bolt snapped but all others came out without an issue. Thought I was some sort of god when all 5 came out before with no issues but alas that was not the case. So out comes the gold plated disco jig to the rescue.

 

IMG_20190505_123337.jpg.d9d511a5231f2b9b60d739d9d9e12612.jpg

 

As described everything lined up perfectly. Bushings went on great and everything was set to go. All I can say is measure twice cut once when drilling out these bolts as one wrong move and suddenly you need a full engine rebuilt. 

 

IMG_20190506_101307.jpg.50e232e87c13b39c2f0face4fd150af2.jpg

 

So onto drilling, plenty of lube is needed.... (giggidy) to keep everything cool and free moving. The kit comes with some carbide drill bits which is a nice touch and very good quality. So after about 30mins of backing it in and out to let the swarf fall from the chamber the pilot hole was done. 

 

IMG_20190506_103401.jpg.54cf7bebb19d41e0602779b2552bd083.jpg

 

Ooo nice and central. So now you move onto the bigger drill to take out the remaining material up to the thread. Same procedure with mounting the fixture and just swapping the bushing out. 

 

IMG_20190506_111013.jpg.d93f721055a1dcbf2d561fdda335f2da.jpg

 

Oft sexy as a drilled hole can get there. Then grab some needle nose pliars and pull the remaining material out the hole. 

 

IMG_20190506_114050.jpg.0ce4eca884fc9c8f8fa51e057ff53671.jpg

 

Replace all of the bolts with stainless studs and that's one side done. 

 

Onto the other side thinking it will be much like the first and bang. First bolt snapped..... Pop second bolt snapped then a 3rd and a 4th... By this point life itself is exiting my body wondering wtf I'm going to do if they all go. With a bit of swearing at the last two and a sturn talking to the last two bolts did come out fine. 

 

So 4 more snapped bolts to do then. Out comes the jig and the same process on the first two without a hitch. 

 

Then thinking it's all going well and I will be racing around on my new exhausts to the local mcds later tonight with a big grin knwokng I've done it myself and saved tons of cash doing so.....

 

Bang..... Whoops bugger...... 

IMG_20190506_140054.jpg.c0011ed94dc6ad5df5e780b4dc85c73d.jpg

 

Rushed it and Pushed to hard without enough lube.... 

 

Sooo at that point I wanted to cry. Gone were the dreams of mcds and exhaust tones and more of regret and annoyance at what a pleb I'd been. 

 

Saving grace was at least the snapped bit came out but I'm now having to order move drill bits hoping the quality is the same or as close as. And 3/16 bits aren't the easiest to come by in the UK I've now found out. 

 

So to at least try and cheer myself up I did test mount the other side. All looking good and lining up as it should. But the other side will have to wait a few days now to be fully complete. 

 

IMG_20190506_153221.jpg.01f4d07e8bd0f4688acba6465bfa82ed.jpg

 

And as this was done on Jack stands in a garage I'm glad to be giving my back a break for a few days. Would have been a doddle on a lift in comparison. 

 

Will also be putting on new lambda sensors as trying to get the old ones off wasn't happening either. 🤣

 

Sooo people wanting to follow the story can follow me on Instagram: @that_purple_cayman 

 

And I will try and keep this thread updated with the progress. 

IMG_20190506_095045.jpg

Great work Equinox! I'm always nervous about drilling manifolds.

 

Looking forward to a video showing off the new noise once done.

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Posted (edited)

hmm and I was told by Carnewal that replacing the cats would be only another half hour job ontop of replacing the exhaust for a GT one ! (I didn't believe it)  Am I missing something? is it an easier job on a 987.2 (CR) ?

 

(Great write up by the way)

Edited by MJ
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Your not missing anything.....Gert is level Jedi when it comes these cars, and he has all the kit for any eventuality. 

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9 hours ago, MJ said:

hmm and I was told by Carnewal that replacing the cats would be only another half hour job ontop of replacing the exhaust for a GT one ! (I didn't believe it)  Am I missing something? is it an easier job on a 987.2 (CR) ?

 

(Great write up by the way)

Yeh he is a guru but I'm pretty sure he means the secondary cats which he is right, are easy to remove in comparison to the cats on the manifolds. Could be wrong though and I'm just mega slow haha!!!! 

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Posted (edited)

987.2 doesn't have secondary cats though. They are on the manifolds. (I think!).

 

Gert wasn't talking about him fitting the cats, as he said he'd need the car a couple of days to do cats to allow the engine to be totally cold. He was trying to convince me they were easy to do as an add on once I got home!  I didn't buy it, knowing how bad manifold bolts can be in any car.

 

cant believe UK P-specialists want up to a grand to swap out manifolds though, greedy basts. 9_9

Edited by MJ

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Last bit of the puzzle has turned up. 

 

Tomorrow will be the day hopefully 😂

 

IMG_20190510_215504.jpg.eb275cf24672afa94ea5cc35923c71a4.jpg

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10 hours ago, MJ said:

987.2 doesn't have secondary cats though. They are on the manifolds. (I think!).

 

Gert wasn't talking about him fitting the cats, as he said he'd need the car a couple of days to do cats to allow the engine to be totally cold. He was trying to convince me they were easy to do as an add on once I got home!  I didn't buy it, knowing how bad manifold bolts can be in any car.

 

cant believe UK P-specialists want up to a grand to swap out manifolds though, greedy basts. 9_9

 

Correct, the 987.2 has both cats in the exhaust manifold.

 

I've always wondered why Porsche never used inconel fasteners judging by how much these snap.  I guess they want their OPCs to have the revenue... 

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Posted (edited)

Game on.... Let's avvveee you! 😂

 

Gotta get your war face on 🤣

 

IMG_20190511_095229.jpg.85dacf37acd2ea405e52bde89a7b71e6.jpg

Edited by Equinox
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Job jobbed 😁👌🍰 now to put it all back together again lol 

 

IMG_20190511_122205.jpg.8e11f1f045b352aa35595f17bcc89138.jpg

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So it's official I have broken down and cried.... 😂 where to begin...... 

 

So got started today with the new drill bits and smashed out the last 2 pilot holes where I left it. Then onto the larger drill bit and straight through those. Offft we are now cooking. Living the dream as one would say. 

 

Then onto chasing the threads and wow everything has gone smooth like butter. Wtf today is going to be my day!!! I own this weekend! 

 

IMG_20190511_111617.jpg.905cd581783e2d9cddc72bb3116db626.jpg

 

So then in go the new manifolds. Ooooo they doo look bloody good all shiny and new. Also sporting 4 new lambda sensors as I could not be fudged to remove the old ones. (luckily) 

 

IMG_20190511_122800.jpg.bb55456979b90691f23ebb5084326066.jpg

 

So now onto chucking on the rear section of the exhaust, on the wheels go and away we go..... Or so I thought. 

 

On goes the exhaust and one side all lined up perfectly. Move round to the other side...... Bugger..... 

 

Not even close. It looks like the flange has seen the other and is actively avoiding getting anywhere near it so has bent itself as much away at an angle as it can.... Dam it looks like this isn't going on today. 

 

The next couple of hours with the misses (yes she got roped in!!!) is spent trying to move things, loosen things and wedge in spacer bits to try overcome this predicament. But alas to no avail they will not fit. 

 

So off comes all the previous work and there they are sat on the floor. 

 

IMG_20190511_174858.jpg.cb01d693b18c6ff8e3ca9818e0937f20.jpg

 

Looks as though one manifold has had the flange welded on it at a slightly different angle which has meant it won't line up one one side atal. 

 

So plan b. Sporting the new hardware and calling on the local exhaust guys who did the secondary cat delete it looks like they are going to adjust their work to fit the manifold or adjust the manifold whatever is easier. However this means I'm back to the standard cats and manifolds until I can drop it round with them.... 

 

Luckily I left the old mabda sensors in place as I cleaned up the old manifolds and have now chucked them back on temporarily. 

 

So all this time and a whole day spent for nothing. Lol atleast there are new gaskets on everything and no more snapped studs or leaks which helps things. 

 

So now with 4 beers in hand I'm off to drown my sorrows but atleast the car is back and working so now more Toyota Yaris (thank god!) 

 

IMG_20190511_194437.jpg.dd60b950893a1c64164cd709cbf921df.jpg

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that's a bummer! not a good advert for Top Gears manifolds either! I'd be fuming having done all that good/hard work. They should now fit them for you as a gesture of good will :)

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4 hours ago, MJ said:

that's a bummer! not a good advert for Top Gears manifolds either! I'd be fuming having done all that good/hard work. They should now fit them for you as a gesture of good will :)

Yeh not great, I have pinged them an email so will see what response I get. Tbh either way I will get it sorted just gave them the chance to twist this in their favour by providing some good customer service. 

 

We shall see what happens 😁 in the mean time I'm enjoying being back bahind the wheel!! 

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