K-Series intake manifold removal

[AndySuperSport]

Hey all,

Anyone got experience of changing the gasket on one of these? I was about to set to work at the weekend but I hit a problem with the nuts/studs on the underside of the intake pipes.

The nuts are obstructed by the various intakes but with a flat section cut into them, I assume to aid removal/attachment.

They take a 13mm socket, but none of mine fit (the stud/intake pipe obstructs it), my dad has found a thin-ish walled socket that may be deep enough/thin enough to clear the stud/intake. I also tried a ring spanner and it fouls on them too. Ideally a ratchet and extension bar is the way forward.

Anyone got a definitive answer that might help us out?

Links to some images below showing the quandry (oh and the haynes manual just says - "undone the nuts, and remove".. helpful!)




Cheers

Andy

[Matt UK]

I've done this job. I can't tell you exactly how I did it all, but do remember that getting at some bits was a bugger of a job!

My advice - take your time, hunt around for the right bits, improvise where you have to and swear a lot!

[DVandrews]

You need a thin walled 13mm socket and an extension with a wobbler end. It doesn't help that the ally manifolds are meant to be bolted on with M8 flange bolts which have 10mm heads and are much easier to do due to the reduced socket size.

Dave

[AndySuperSport]

Dave - I thought it was strange that the space was so restricted to not allow easy use of a standard 13mm socket. Thanks for the input. I'd much prefer to switch to 10mm for future use but I suppose that would involve changing the studs, so maybe not. I'll hunt out some wobbly extensions!

Matt - the swearing has already begun, hence this thread

I'll let you know how I get on

[AndySuperSport]

Update

Managed to find a thin wall socket in an old set my dad had, plus a UJ adaptor.

Set about undoing the nuts/bolts some of which were very loose, to the point I thought the socket was rounding on them as I was applying next to no pressure.

After undoing yet more bits out of the engine bay to give me some space, including one of the angled bars with loads of wiring loom attached to it, I've managed to get the manifold off to expose the old gasket.

The old one is a mess, deteriorated in some parts and perished. Admittedly some damage may have been done when I remove it but some tears looked quite old and now there's bits of old gasket stuck to the block.

Am in the process of cleaning it up with white spirit and trying to scrape off bits before the slog of putting it all back together.

[AndySuperSport]

Another update

Got it all bolted back up and coolant topped up, but sadly it hasn't fixed the problem, so I guess it wasn't a vacuum leak around there then. I'm going to pick up a can of carb cleaner at the weekend and spray it around just to be on the safe side.

So far renewed/replaced:
Ignition coil, HT lead, dizzy, rotor, plugs, fuel filter, lambda, coolant temp sensor, air temp sensor, checked ECU for signs of damage/corrosion, replace fuel vapor trap, cleaned out air intake, replaced fuel, tried fuel additive.

Leaving:
Timing to be checked, fuel pump operation, injectors

Incidentally, can anyone tell me if the 1.4 K-series Supersport has a funny timing setting? I think I recall reading something about it online but for the life of me can't find it again.

Here's a photo of my recent attempt to get it running right