Exhaust Manifold Questions

[95er97gsxtreme]

I hope this is the right area to be posting this. I already know what the problem is so need your answers to figure out the next step. Here's the deal:

My friend has a 90 Laser RS Turbo. Really been dumping money into it. Head, Head gasket, Timing belt and associated belts. You name it as far as things that can go wrong they had when he got the car.

Here is the current situation:
Got an exhaust leak and checked it out with a shop. The exhaust Manifold is the problem. It is cracked and also warped. The shop said they would shave it and weld it and that would fix the problem. Sounds kinna like a waste to me.

Found a brand new exhaust manifold, mounting hardware and gasket for about 100 bucks. Plan on doing this repair ourselves.

Here's the questions.

Is that a good price for the new mani?

Is this a job that can be done easily with the standard tools, Chiltons, and DSM Manual cd?

Any things you need to specifically watch out for when doing this?

What else do you need beside the mani, bolts, and gasket?

Thanks allot,
Howie

 

[91gst]

Well it should be a fairly straight forward install. You may have to remove the power steering or at least loosen it from the bracket and try to move it cause there are some bolts on the side that are fairly hard to get to. Other than that it isnt that hard. Also you should get a new gasket that goes in between the turbo and exhaust manifold. Check this out for some better pics...... http://www.vfaq.com/index-main.html
In this they are installing a 2g exhaust manifold but its basically the same thing. Hope this helps. Good luck.

 

[Defiant]

Lots of PB Blaster, extension handles, and be prepared for a broken stud or few.

This is for a 1G, but should help:

http://vfaq.com/mods/turbo-swap.html

 

[jdmawd]

Definitely go for the 2G mani that you found for $100. Soak the studs down with WD 40 or PB blaster for at least a good 30-40 minutes. the nuts will come of like butter. When I removed my stocker from my 92 with 129K on it, that's what I did.

you will have to pull the power steering pump to get the lower drivers side stud. Dont let them weld your old mani. just replace it with something better like a 2G or evo like you suggested.

 

[jbillakdsm]

I changed off my manifold to a 2g without having to remove the power steering pump. I had no trouble getting at it to get it off and the new one went in without incident. I used a knuckle to get it out and in and I have a torque wrench from Snap-On that fit right in there. Maybe I was just lucky.

Use PB Blaster like it's your best friend. I soaked my bolts every day for two days before I attempted to pull mine and things went rather smoothly considering I had 4 studs broken off. Not one required more than a vice-grip and some muscle to break loose.

Needs: 1) A new bolt to replace the stud that runs from the turbo to the manifold, saves you a ton of time if you ever have to take it apart again. 2) Make sure you grind a little off the lower right hand corner of the manifold so that it clears the power steering pump. 3) Get yourself some new metal gaskets ( 7cm manifold to turbo and EVO for turbo to O2 housing IMO). While you have everything apart, you might as well do some porting so that everything matches, you'd be amazed at how much you can pick up by matching everything. PM me if you need an entire list of what I used when I did my manifold swap. Check my gallery for pics.

 

[BUCK]

The VFAQ notes it but just remember that the lower middle stud goes DIRECTLY into the Head OIL Supply Galley.

 

[98TsiAWD]

Chad, I can help you guys with that if you need. Being as the head was just off the car you shouldnt need any new exhaust studs (probly already been replaced?), I wouldnt think you will break any since they have been on for such a short time.

Its cake 10 nuts on the exhaust manifold to head, then 4 into the turbo. Now here is the shitty part, it probly has a stud that comes out of the turbo up into the exhaust manifold and then a nut ontop of it.
This stud might make you have to pull the whole turbo out of the car, if it wasnt for this stud you can remove the exh. manifold with everything else still on the car (other than the ps pump bracket).
I removed that stud and just put another bolt in its place like the other 3.

 

[steve]

Save yourself some grief and replace all the studs in the head for the exhaust manifold. The ones that aren't broken now will likely snap when you go to torque the manifold down after replacing it. Just put two nuts on the stud and tighten them against each other then turn both to unthread the stud.

The 2G or EVO III exhaust manifold will need some grinding in the lower drivers side corner to fit per the VFAQ. http://www.geocities.com/dan0myte/mods/exman.html
It took me two seconds witha bench grinder to make EVO III manifold fit. But you can use a die grinder like this.

You must be logged in to view this image or video.

Steve

 

[BUCK]

The VFAQ notes that the lower middle stud goes directly into the Head Oil RETURN Galley - so it's under no pressure - I screwed up & said Supply earlier.

 

[pneumo]

Meh, no biggie, BUCK. The point was well taken; mess up the middle stud and oil goes everywhere.

As for the stud holding the manifold to turbo, I also used lots of penetrating lubricant and twisted it off with a big set of vice grips.

 

[MiNiONTSI]

I'm going to be swapping on a 50trim soon. I have a 2g manifold and a tubular o2 sensor housing.

Is there a way that I can just remove the turbo, 02 sensor housing, and manifold all at once, or is there just no way that the thing will come out of the car all together like that?

 

[BUCK]

FYI - I bolted up a 95 Exhaust Manifold to my 91 & didn't have to grind anything at all - it fit like a glove.

 

[BUCK]

And I think the Exhaust manifold, Turbo & O2 Housing would easily all come out as a package - pull the radiator first thing of course.

4 bolts - 2 Connectors & 2 Hoses - the ONLY easy job on a DSM as far as I can tell - I pull it for almost everything it seems - It's only 1 gallon of Antifreeze for a 50/50 mix, system holds 2 gallons.

 

[98TsiAWD]

Originally posted by MiNiONTSI
I'm going to be swapping on a 50trim soon. I have a 2g manifold and a tubular o2 sensor housing.

Is there a way that I can just remove the turbo, 02 sensor housing, and manifold all at once, or is there just no way that the thing will come out of the car all together like that?

Yeah the manifold/turbo/o2 housing will come out of the car in one piece. Ive done it, just unbolt the oil drain, oil feed, and unhook your water lines, intake pipe, downpipe, and remove the exh. manifold studs. You will have to loosen the 4 bolts into the turbo to make room for an extension to fit between the turbo/exh. manifold to get the bottom bolts out.

 

[95er97gsxtreme]

Thanks for all the advice I do appreciate it. My friend has a 90 laser RS Turbo and we are going to be getting the 1g Ex Mani new and put it on. His car is pretty much parked for the winter barring any middle of the night drift opportunities, so we will be handeling this come spring.
Thanks again and I hope everyone else learned some things from all the great replies I got. I know I did.

Thanks,
Chad