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Jokerman170 · Administrator Joined: 12 Feb 2011 Posts: 16

[QUOTE=Danny;49223]This guide covers Euro 3 and Euro 2 HGT’s, Euro 2’s don’t have the lambda sensors/Pre cats in the downpipe. Euro 2's have a Lambda sensor near the front of the main cat. Before you even start you need to get a new exhaust manifold gasket Part No.73502761. I'd also suggest a new rubber doughnut for the top radiator support too, it costs penny's and they always fail so while its off it'd be rude not to.

First disconnect the battery and put the car up on axle stands.

Disconnect the two lambda sensors,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the two bolts holding the heat shield to the top of the manifold, I think there are two lower down but tbh I ripped mine off ages ago,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the bolts holding the lambda sensor wire housing from the rocker cover,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

And unclip it , drop the wire down between the rad and exhaust so its down on the floor.
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Go underneath the car and undo the bracket holding the heat shield and down pipe to the block, remove the bracket completely and put it away somewhere as you don’t need it.
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the two bolts connecting the down pipe to the cat,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Pull the exhaust rubber off the down pipe hanger,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the four nuts connecting the down pipe to manifold, one from the top,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

And three from the bottom,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Remove the down pipe complete with lambda sensors from under the car,

Undo the eight manifold nuts using a 12mm socket,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Two are a pain which is why you need a ¼ drive socket set to get access to them,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the bolt holding the radiator top bracket,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

View from inside the engine bay with bracket removed,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Pull the manifold out from the top of the engine bay,
View of the inside of the down pipe (Euro 3), looks pretty restrictive,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the bolt holding the dip stick support bracket and swivel the dip stick out of the way,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Undo the nut and bolt holding the water jacket support bracket,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

And remove to allow removal of the manifold gasket,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Clean up the face of the head with a rag/oiled emery paper to ensure a good gas tight seal.
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Unbolt the lambda sensors from the down pipe and install into the Supersprint down pipe ensuring there round the right way,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Fit the new manifold gasket and refit water jacket support bracket, (The old gasket is a compression gasket so can only be used once),
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Now fit the Supersprint manifold, it’s a right pain which is why you undo the bracket on top of the rad so it will move over just enough to get it on,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Once its on put the eight nuts back on and tighten them up in a criss-cross fashion, final tightening torque is 25Nm’s,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Now get under the car and fit the front section of the down pipe, its very tight so use a rubber mallet, you’ll know when its on far enough as when you hit it the sound will change from a ping to a thud, (You should'nt use exhaust paste on any joint before the cat or the fumes will pollute it)
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Tighten up the two allen bolts but be careful not to strip the threads. If you do a nut and bolt would do the same job,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Check the lambda sensors are clean as they take a reading through these small holes to compare the exhaust gases to,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Bolt the rear section of the down pipe to the cat,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

And reattach the exhaust rubber
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Fit the compression bush and bolt up the joint as tight as possible,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Plug the Rhs lambda sensor back in,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Feed the Lhs lambda sensor wiring up, It must go this side of the air con pipe or you won’t be able to clip it back on properly,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

And bolt it back up,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Clip it back in,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Re connect the sensor,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Refit the top radiator support bracket removed earlier.

Reconnect the battery and start it up, check for leaks/engine light. (It will bellow smoke like anything when first starting it)

After a few miles it will melt your fan casing slightly but its nothing to worry about,
Guide : HGT - Fitting a 4-2-1 Supersprint Manifold Guide : HGT - Fitting a 4-2-1 Supersprint Manifold

Now go out and annoy old people.[/QUOTE]