Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Plus 4 GDI Aero Racing Manifold & Exhaust Upgrade

So let the story begin..........

First I removed the exhaust system. Because I treat my exhaust mountings as a service item, and restore them every year or so, it only took a few minutes to remove the exhaust. For the refit, I had bought new bobbins and stainless U bolts. A couple of the bobbins had the studs turning in the metal discs.

I then removed the sensors. They are not the same. Usually I have trouble with latched electrical plugs, but these were easy. A simple thumb press and they slid apart.

Here's a funny thing........the upstream sensor which I removed was a light matt grey, like an old leaded fuel tailpipe.

The downstream sensor, after the cat was covered in black sooty deposits..........I just can't understand what's going on with that.

The leads need extending and I got these from the factory. Upstream, and downstream.........





To remove the manifold and cat, the engine needs to be lower. One option is to remove the cam cover, but I'd rather not do this. I removed the offside engine mounting, and lowered the engine as far as I could, but it wasn't enough, and there's a risk of damaging other things. So out came the hacksaw, and I cut the system in half just below the cat. Then it lifted out!



At this stage I wrapped the manifold, but I don't like the look, and the next day I took it off.....just a personal thing. The shiny pipes look so much nicer. The manifold gasket is shim steel, and I reckoned I could reuse this, which I did. The new manifold bolts on easily with five nuts.





These are the sensor plugs in the engine bay.



I also found that the underwing protector was hanging off......just on this side, so I pulled it off, and replaced with Reflect-a-cool.

This is the remains:



What I pulled off:



And as replaced:



To be continued....................