From the first moment I got my Spyder, the first recommendation from everyone was "gut your cats!" But hey, that manifold is like right next to the motor! That's mechanical stuff! How am I supposed to deal with that? Well it turns out, that with the proper tools and a lot of time on your hands, its not that difficult.
Tools and consumables:
From my little precat removal experience, I've found out that the following is essential to an stress-free experience. I strongly suggest not starting this little project without:
1) deep and regular hex sockets (esp 12mm and 14mm)
2) breaker bar
3) PB Blaster
4) socket extension
5) lots of daylight
The essential tools that are required are:
1) ramps
2) 14mm, 12mm and 10mm sockets and ratchet
3) 2 gaskets from MrT (see diagram below)
Optional but nice to have are:
1) new studs
2) new bolts
Procedure:
Here's a diagram of the entire disassembly process. Please refer to this often:
For more diagrams, check here.
The first step is to put your car on ramps. Remember to have someone always spot you when using ramps. Also, keep your handbrake engaged for more control:
Access to the nuts that need to be removed from underneath the car is hindered by the rear diaper. You will have to remove this with a socket wrench. The screws are easily removed:
You can see the spots where screws need to be removed here:
It is also eases access if you remove the mid-diaper. The screws and poppets that need to be removed are highlighted:
From underneath the car, take a gander at the "3 Amigos", they will be your biggest challenge in this project. Refer back to the diagram to see where this is in. It's in Area 4 in the lower left hand side of the top diagram, near the 2 gaskets:
Use PB Blaster or similar product and drench the 3 Amigos. PB Blaster is cheap, frustration is expensive. Let sit for a couple of minutes (or hours, or days). Using a breaker bar, 12mm DEEP HEX SOCKET, and socket extension, pry the nuts loose by rotating counter clockwise.
It is essential that your socket is HEX shaped, as any other shape will easily make the nut lose it's thread due to the amount of force being applied.
You will need a DEEP SOCKET, as the studs extend past the end of the nut, making it difficult for your socket to have sufficient grip.
You will need a socket extension, as the location of the nut is very difficult to get at (maybe even impossible) without a socket extension.
After removing the 3 Amigos, you will need to remove 2 bolts that brace the manifold to the frame. They are directly to the top of the 3 bolts you just removed. Use PB Blaster to loosen. The left bolt is 14mm, the right is 12mm. There may not be room to use the breaker bar.
You're done with removing the nuts and bolts from underneath the car! Yay! Now to deal with the bolts on top. Pop the lid off the engine bay, and remove the rear strut bars. Instructions for this can be found here:
http://spyderchat.com/forums/index.php?sho...c=44014&hl=
Now to remove the top heat shield, which is held down by 4 bolts. Refer to the 1st diagram, this will be Area 2, top left hand side. You will see 2 bolts. Use PB Blaster to loosen the bolts, and use a 12mm socket and the breaker bar to remove the bolt by rotating counter clockwise:
Refer to Area 6 on the diagram. This is where the last 2 bolts that hold down the heat shield are. Use PB Blaster to loosen the bolts, then remove with a 12 mm socket and ratchet. There will not be enough room for a breaker bar, but the bolts will hopefully give before the bolts lose thread or snap
The heat shield is now loose, but the 02 sensors need to be remove first. Refer back to the diagram. This will be in Area 1. Left side:
Right side:
The 02 sensor harnesses can be disconnected easy, by pressing on the tab to unlock, then pull apart:
Now to remove the 02 sensors. You will need an 02 sensor socket. This is looks like an ordinary socket, with a slit on the side for the sensor wire to pass through:
Soak the 02 sensor in PB Blaster. Wait a couple of minutes. Place the 02 socket on the 02 sensor, passing the wire through the slit, like so:
You can now remove the 02 sensor using a ratchet, or a breaker bar if space allows:
Here's what it looks like removed:
After taking off the other 02 sensor, you're now free to take off the top heat shield:
You've now exposed the manifold! See Area 3 in the diagram on top for reference. There are 5 12mm bolts that connect the manifold to the engine. Use PB Blaster to loosen the bolts. Use 12mm DEEP SOCKETS and the breaker bar to remove the 5 bolts.
Pull out the manifold, and remove the heat shields from it. You're halfway there! Now to re-assemble everything!
Tools and consumables:
From my little precat removal experience, I've found out that the following is essential to an stress-free experience. I strongly suggest not starting this little project without:
1) deep and regular hex sockets (esp 12mm and 14mm)
2) breaker bar
3) PB Blaster
4) socket extension
5) lots of daylight
The essential tools that are required are:
1) ramps
2) 14mm, 12mm and 10mm sockets and ratchet
3) 2 gaskets from MrT (see diagram below)
Optional but nice to have are:
1) new studs
2) new bolts
Procedure:
Here's a diagram of the entire disassembly process. Please refer to this often:
For more diagrams, check here.
The first step is to put your car on ramps. Remember to have someone always spot you when using ramps. Also, keep your handbrake engaged for more control:
Access to the nuts that need to be removed from underneath the car is hindered by the rear diaper. You will have to remove this with a socket wrench. The screws are easily removed:
You can see the spots where screws need to be removed here:
It is also eases access if you remove the mid-diaper. The screws and poppets that need to be removed are highlighted:
From underneath the car, take a gander at the "3 Amigos", they will be your biggest challenge in this project. Refer back to the diagram to see where this is in. It's in Area 4 in the lower left hand side of the top diagram, near the 2 gaskets:
Use PB Blaster or similar product and drench the 3 Amigos. PB Blaster is cheap, frustration is expensive. Let sit for a couple of minutes (or hours, or days). Using a breaker bar, 12mm DEEP HEX SOCKET, and socket extension, pry the nuts loose by rotating counter clockwise.
It is essential that your socket is HEX shaped, as any other shape will easily make the nut lose it's thread due to the amount of force being applied.
You will need a DEEP SOCKET, as the studs extend past the end of the nut, making it difficult for your socket to have sufficient grip.
You will need a socket extension, as the location of the nut is very difficult to get at (maybe even impossible) without a socket extension.
After removing the 3 Amigos, you will need to remove 2 bolts that brace the manifold to the frame. They are directly to the top of the 3 bolts you just removed. Use PB Blaster to loosen. The left bolt is 14mm, the right is 12mm. There may not be room to use the breaker bar.
You're done with removing the nuts and bolts from underneath the car! Yay! Now to deal with the bolts on top. Pop the lid off the engine bay, and remove the rear strut bars. Instructions for this can be found here:
http://spyderchat.com/forums/index.php?sho...c=44014&hl=
Now to remove the top heat shield, which is held down by 4 bolts. Refer to the 1st diagram, this will be Area 2, top left hand side. You will see 2 bolts. Use PB Blaster to loosen the bolts, and use a 12mm socket and the breaker bar to remove the bolt by rotating counter clockwise:
Refer to Area 6 on the diagram. This is where the last 2 bolts that hold down the heat shield are. Use PB Blaster to loosen the bolts, then remove with a 12 mm socket and ratchet. There will not be enough room for a breaker bar, but the bolts will hopefully give before the bolts lose thread or snap
The heat shield is now loose, but the 02 sensors need to be remove first. Refer back to the diagram. This will be in Area 1. Left side:
Right side:
The 02 sensor harnesses can be disconnected easy, by pressing on the tab to unlock, then pull apart:
Now to remove the 02 sensors. You will need an 02 sensor socket. This is looks like an ordinary socket, with a slit on the side for the sensor wire to pass through:
Soak the 02 sensor in PB Blaster. Wait a couple of minutes. Place the 02 socket on the 02 sensor, passing the wire through the slit, like so:
You can now remove the 02 sensor using a ratchet, or a breaker bar if space allows:
Here's what it looks like removed:
After taking off the other 02 sensor, you're now free to take off the top heat shield:
You've now exposed the manifold! See Area 3 in the diagram on top for reference. There are 5 12mm bolts that connect the manifold to the engine. Use PB Blaster to loosen the bolts. Use 12mm DEEP SOCKETS and the breaker bar to remove the 5 bolts.
Pull out the manifold, and remove the heat shields from it. You're halfway there! Now to re-assemble everything!