janspeed manifold diy install by zirconmr2

7 minute read

janspeed manifold diy install 

Compliments of zirconmr2 @  totalmini.com

4-4-2014

Heres how to swap a manifold, or at least how I did it….

First pop the bonnet

Remove strut brace if you have one

Now look behind the engine, you will see a heat shield over the manifold, this is held in place with 2 (usually, mine only had 1 ) 13mm bolts, remove these bolts and then wiggle the heatshield out.



Now look at the manifold, there are 8x 10mm bolts to remove from the head, I tried mine with the engine cold and they came out easily, too easily imo, some people recommend getting the engine hot to aide removal.
Take the 10mm bolts out.



Now unclip the pre-cat lambda sensor, its on the top right of the engine, follow the wire and unclip it too



Time to get the car in the air, jack and stands, ramps, lift, whatever weapons you have. Get it as high as you can, and make sure its secure.

Get under the car and undo the post-cat lambda sensor with an open end 22mm spanner, tuck the sensor under the heatshielding out of the way.



Now remove/undo the bolts connecting the manifold to cat, these can be anything between 14mm and 17mm depending on your exhaust.



Now begin to lower the exhaust, when its down a bit, remove this heat shield, 2x 10mm nuts and 2x 8mm hex screws, wiggle it out.



These next 2 pics are of the post cat sensor showing where it clips and where the plugs is situated, (its easy to change it tim, you don’t need to remove the heat shield just jack up the car and unclip the plug, bend the metal clip holding the wire, and remove the sensor with a 22mm spanner, should take all of 5 minutes)




Now lower the manifold until you get the flange to the front ARB, you will need to move a few pipes but its not difficult, now slip one end over the ARB I started with the passenger side, push the cat end towards the drivers side and the manifold will just about come free, lay it nex to your new manifold and compare, the stock mani is looking very restrictive by comaparison..





next you need to clean the surface of the head, make sure all signs of gunk and oil are gone.

Now in the reverse way slip the new manifold over the ARB, because of the shape of the manifold it’s a little tricky to get over the ARB, but its definitely doable, so persevere. Once the manifold is over the ARB, slid the heatshield you removed into place and secure it,

now from above I used 2 zip ties to hold the gasket to the manifold, some use superglue, other used a different method, zip ties worked fine for me,

next I pushed the mani up to the head and loosely connected in the the rear exhaust section to hold it in place

get your 8x 10mm manifold to head bolts and locate them loosely in the head, once you have them all in place, tighten up to torque spec.

reach down a grab the pre-cat sensor wire, feed it back up the the top and plug it in, clip the wire in place

replace the manifold heatshield and clip the wire to it.
I didn’t put it back right away, it need a bit of trimming to fit over the janspeed



Get back under the car, fit your choice of sports cat or decat making sure you fit gaskets at both ends, I put the post-cat sensor in the decat pipe before attaching it to the manifold so the wires were not twisted




You should now be done and have no stray parts lying on the floor, if you have you’re a muppet! Start the car and check for leaks, no leaks? Lower the car back to the ground.

I left the car running for 5 minutes before touching the throttle, no idea why, just figured that’s what I would do?

Then give the loud peddle a nudge, this is now my favourite mod, it just doesn’t stop popping, its hilarious and pretty damn loud too!

videos:

Before with direnza exhaust and stock manifold


After with direnza and janspeed manifold and decat

4-5-2014

aint been out for a drive yet, the main road here was closed due to a young driver hitting and bus shelter and a tree and killing his passengers (thats why i wasnt working, and was able to fit the manifold, couldnt get into work). dont know who it was yet, chances are i know them or the family but its pretty sad when these things happen.

the noise does give me a childish grin at the moment, i have a feeling on the road it might be too loud with a decat, ok if your 20, but at a few days from 40 it will stink of midlife crisis!
the sports cat will quieten things down a notch though if thats the case.