Well, inlet removed, de-flapped, M8 bolts sealed in lieu of the flap bush/bearing. No error messages...lets see how the commute to work goes this evening.
I didn't fully remove the alternator...just slid it forward enough to allow the inlet manifold to pass.
Slim 1/4 inch ratchet to lift the belt tensioner.
The bottom bolt was crossed threaded on the manifold. Much easier to remove the bottom bracket.
I removed the brake servo hose from the servo rather than risk breaking the push fitting on the manifold.
How to remove non EGR manifold (at your own risk exercise safe practice and judgement etc etc) :
1) Remove battery and engine cover
2) Remove air box and inlet pipe work. Remove servo vacuum hose from servo and unclip from various supports
3) Support engine and remove top engine mount to give easier access to serpentine belt tensioner. Use 1/4" ratchet drive to lift tensioner
4) Remove belt from alternator and the 4 bolts holding alternator to block
5) Slide alternator as far forward as possible
6) Remove 13mm bolt that holds inlet manifold bottom holding bracket to engine block. Remove engine breather and hoses from inlet and cam cover.
7) Disconnect and remove throttle body.Disconnect ECU wiring (gently pull the black plastic clip backwards as you lift the metal clip forward) 10mm bolt for earth lead.
8) Remove ECU ( 3 x 10 mm bolts) and 10mm bolt holding oil dipstick tube to manifold (remove dipstick from tube too)
9) Remove fuel vapour hose from inlet manifold and the other end with the green release clips, unclip vapour valve body from bracket and position out of the way. Disconnect the swirl flap wiring connector that is next to the vapour valve
10) Remove the uppermost small coolant hose from header tank and the 10mm bolt holding it to support bracket. Postion out of the way.
11) Remove 2 x 10mm nuts holding loom tray in position, this allows some more movement/room
12) Remove Fuel pressure regulator, no need to remove wiring, just position out the way.
13) Remove MAP sensor (10mm bolt) then disconnect wiring plug.
14) Disconnect various clips/cable ties holding wires and multi connector blocks to inlet manifold. Check all sensors and connectors are removed and out the way
15) Remove 2 x 10mm nuts and the 10mm bolts from mating face of inlet manifold
16) Carefully wiggle dipstick tube out of the way as lifting manifold clear
Refitting pretty much the reverse.
