It was certainly a battle. I ended up taking the headers out to get to the flare nuts. I managed to get 2 out, just barely, the rest snapped off, leaving the pipe and thread still attached to the header. So i cut the pipe at the exit, welded up each hole, filed it down, took an angle grinder with a wire brush to the headers and gave them a coat of high temp paint, just to hold off the rusting a bit and clean up the look a bit.
Swapped out the 02 sensor too, the one in there was sure stuck real good. I fear i clipped the wire when reinstalling (should have removed spark plugs for easier access), so i hope it's working!
Still getting smoke shoot out the exhaust after starting the engine if has been run within a short timeframe (next morning it starts clean). Fuel smell seems to have improved since installing a new thermostat. The one in there was stuck open, so it's a lot warmer in the car now and runs at a nicer operating temp. I read that the ECU is in closed loop mode until coolant temp reaches 76c, meaning it gives extra fuel i believe - temp was sitting at about 70c, often cooler when driving on the motorway on a cold day. Now it sits at about 82c.
Also flushed the cooling system, took out the coolant reservoir and gave the inside a good clean out. Cleaned out the throttle body with carb cleaner, lots of black residue around the butterfly valves and behind them. Didn't know it had a MAF sensor so i ordered some MAF cleaner spray but it came after i put it all back together, so that's a future job.
I also changed out the hoses and belts. Seems that the voltage dropping at idle issue has pretty much stopped, so even though the belts looks spot on, no cracks etc. perhaps they were getting near the end of their life span and stretching when under tension. Hoses were original and not even a hairline crack, but thought i'd change them for good measure as a heater hose went a bout a year ago. Top hose was a "direct" replacement
The before header of one side:
The after header on the other side:
Lot cleaner engine bay and slightly easier spark plug change as well. Take it you've removed the pump as well and put a shorter belt on?
