Today I decided to fit the NA manifold and throttle.
I removed the butterfly, removed the lump of plastic from it and silver soldered the hole up, filed it down, sanded it smooth with some 800, forgot to take a photo and refitted it to the throttlebody.
The old manifold is a piece of cake to remove. Essentially fuel rail and injectors, spark plug cover, breather hose, intake hose, throttle cable, one bolt securing the dipstick tube, one supporting the underside of the plenum and 7 bolts holding the manifold to the head, there are about 6 vacuum hoses of varying sizes and a couple of misc clips and screws also.
Refit is exactly opposite and equally as easy. The only difference being that the intake pipework no longer fits onto the throttle. The best option here is to buy a specially made hose from Snabb
http://www.snabb.us/NA-Throttle-Body-Hose-for-Turbos-93-97-850_p_30.html
I didn't take that option. I simply purchased a standard 2 1/2 to 3 inch silicone joiner. Trimmed it down as short as possible making sure to allow enough length for the clamps to do their job and inserted a 50mm long piece of 2 1/2 inch exhaust tubing in the small end. I then trimmed about 20mm off either end of the original hose and slipped the pipe inside until the new and old pipe were snug against each other. I estimate it extended the pipe by about 15mm. There is enough flex for this to fit ok. and it works fine, I will however, order the Snabb pipe and change it over at a later date because it is much neater.
While I was mucking around I cut the rear muffler out and added a new 3 inch tailpipe. Sounds a little louder and deeper, but not dramatically different. I will build a full 3 inch exhaust for it, but am not going to bother with that until i get the new turbo. I am going to change to an angled flange at the same time.
Overall it is a noticeable improvement with no noticeable negatives. In fact the US guys are determined that I will see a fuel economy increase... we will see.
