Exhaust manifold replacement checklist

[ErikTande]

I'm going to be replacing my cracked exhaust manifold in my 1990 GSX, and I need some help with a checklist of tools and parts before I start.

Is it in my best interest to replace the manifold studs? Or should I not worry about that now?

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Here's my list of stuff I have already:
______________________________________________________________________

- 2g exhaust manifold and gasket - (craigslist combo deal for $30 )
- 10mm flex head ratchet wrench
- 12mm flex head ratchet wrench
- regular metric wrench set
- metric socket set
- standard socket set
- anti seize
- PB Blaster




Things I need ( I think )

- Manifold / turbo bolts (EXTREME PSI : Your #1 Source for In Stock Performance Parts)
- 6cm manifold turbo gasket (Turbine Housing Inlet Gasket (DSM) - Modern Automotive Performance)
- m10 x 1.25 tap (just in case)

 

[ENICKB]

Looks like your ready, I think you need 14mm for the turbo bolts, but you should have that in your set. I usually use a jack under the downpipe to support the weight of the turbo... Alligning the bolts can be a pain. Remember to get them all started and threaded before you tighten anything down, if possible. DONT CROSS THREAD! And remember your head is made of alluminum. If your brave, you may want to port the exhaust manifold and turbo first.

 

[ErikTande]

Looks like your ready, I think you need 14mm for the turbo bolts, but you should have that in your set. I usually use a jack under the downpipe to support the weight of the turbo... Alligning the bolts can be a pain. Remember to get them all started and threaded before you tighten anything down, if possible. DONT CROSS THREAD! And remember your head is made of alluminum. If your brave, you may want to port the exhaust manifold and turbo first.

Thanks! Where do I place the jack to support the turbo? Is my placement in the pic correct?
I don't have the experience or tools for porting, so I'm just going to bolt it on and call it good. I'lll be putting on a different manifold and turbo in a year anyway (hx35).

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Also, torque specs, does this look right? From here:http://www.dsmtuners.com/forums/newbie-forum/382306-torque-specifications-spec-bolt-nut.html


-Exhaust manifold to turbo: 40-47 ft. lbs.

-Exhaust manifold to head: 18-22 ft. lbs.

 

[99ECLIPSEGSXDSM]

You can support it buy putting a jack under the downpipe buy DO NOT jack it up buy the downpipe. You can do a lot of damage.

 

[ErikTande]

You can support it buy putting a jack under the downpipe buy DO NOT jack it up buy the downpipe. You can do a lot of damage.

Yep, I got that Is the jack location correct if I want to jack the car up?

 

[agentorange313]

I personally hate those type of gaskets. They rust up and blow out very quickly.

Do you have your stock 2-ply gasket still? That one is overall better, and can be reused. The upgrade would be the 4-ply evo exhaust gasket, same flange so it works with 90-99 DSMs.

You might need a swivel head to get to the manifold bolt near the power steering. I removed the shield and have little hands so I could get in there with a regular wrench.

You can jack it up from the middle of the cross member. Although I have never had to jack a car up to change the manifold/gasket. The stock turbo is being supported by the downpipe attached to the o2, the coolant lines, oil feed and return. It will be fine if you are swapping manifolds. Plus that jack position would only support the frame of the car, the turbo is not support at that location.

the part you have labelled Jpipe is usually called a downpipe for DSMs. You can support the turbo from that location.

I would also replace the turbo inlet gasket while I was in there.

 

[ErikTande]

Can anyone recommend a tap in case I need one? I assume this will work:

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[ame]http://www.amazon.com/Helicoil-5543-10-Metric-Thread-Repair/dp/B0002SRG34/[/ame]

 

[99ECLIPSEGSXDSM]

Your jack spot is where I jack mine up