1.6 na exhaust replace

[rodpaslow]

I have a 90 1.6 na I need to replace the down pipe & exhaust manifold.  I have a new one to get rid of the spring connection with a two pipe unit from an old gasser I once had.

Its a son-of a gun; can you remove the exhaust without having to remove the intake?  If so how do you see/get two the two bolts under the intake?

I spent better part of 2-3 hours trying to get at one of the inner (2nd in from the end) intake bolt.  Can't get a wrench on it.  Do you need a mirror to see what's going on?

[R.O.R-2.0]

I have a 90 1.6 na I need to replace the down pipe & exhaust manifold.  I have a new one to get rid of the spring connection with a two pipe unit from an old gasser I once had.

Its a son-of a gun; can you remove the exhaust without having to remove the intake?  If so how do you see/get two the two bolts under the intake?

I spent better part of 2-3 hours trying to get at one of the inner (2nd in from the end) intake bolt.  Can't get a wrench on it.  Do you need a mirror to see what's going on?

i just pull the intake manifold.. its only 6 bolts, and it makes things 100x easier.

unless you are a big guy like me, and can reach the passenger side manifold bolts from the DRIVERS SIDE, then just remove it..

or give it a go with the intake still on.. but beware, you remove the inside exhaust mani nuts by braille, not by sight..

[rodpaslow]

That's the problem, i tried removing the na intake bolts and I can't seem to get a wrench (6 point allen 6mm) on the inner ones at all. I have removed the outer two and can't seem to get a wrench on the others.  I have a spare turbo intake, I'm almost considering cutting the NA one so I can get at the allen head bolts to remove what's left of it and install a spare turbo one.  I remember removing one a long time ago, I don't remember it being this hard to remove..

[CrazyAndy]

You probably need a longer allen wrench, like a 6mm allen ball socket.  That's what I used, as the inner bolts are too short for regular short allen sockets.  Have you tried a long allen key with a 6 mm wrench on it?

[Blocksmith]

Yeah, ball head allen, extensions if ya need 'em, and make sure the bolt is clean enough on the inside. Feel down in there, and scrape a bent paperclip or something around; wash it out with brake cleaner or aerosol of your choice. If that doesn't work, you may have rounded out the inside of the bolts already, in which case you will have no choice but to cut it off...

[ORCoaster]

To remove the intake six Allen head bolts out I use a 3/8ths rachet with a couple short extensions on it.  I have a hex set that has 3/8th ends on it so it is a bit of a fight to get the hand around up and under the manifold to plug it into the bolt.  But I have done it several times now.  I look through the openings between the individual pipes and if possible use them to help align the hex end to the bolt.   

Don't forget the nut on the back that goes to the exhaust as well.  I did that last head gasket.  Got all the hex bolts out then couldn't figure out why the darn thing wouldn't let go of the engine.  It was wiggling but still firmly attached. 

I wonder if a 45 pt would do better that the 6 mm hex wrench? 

[rodpaslow]

I don't have a ball type allen 6mm,  I have to go and get one for my 3/8 and see if that helps.   I got my fingers crossed that it does!

[745 turbogreasel]

If you have a file or a grinder, it's not too hard to make a ball allen.

[R.O.R-2.0]

you dont need a ball allen.. use friggen extensions..

if that doesnt work, i use my long reach 6mm bit..

[ORCoaster]

Harbor Freight has Friggen Extensions on sale this week.  An Assortment Pack for 2.99.  Buy two and get a real combination selection going. 

[745 turbogreasel]

Harbor Freight has Friggen Extensions on sale this week.  An Assortment Pack for 2.99.  Buy two and get a real combination selection Pile of busted parts going. 

Fixed that