Best way to remove Exhaust Manifold?

[tsi1991awd]

My 1g exhaust manifold has cracks in it. I have an Evo3 manifold that I am going to install. But I'd like to know what the best way to remove the manifold bolds/studs would be. The top ones will be no problem. The bottom ones are going to be the tricky ones it seems.

Also, one of the bolt heads are broken off. Its one on top, in the middle....is just one broken bolt enough to cause an exhaust leak?

One more thing...what's better, a Cometic manifold gasket or Mitsu 4 layer?

 

[Teflon]

Use a deep socket with an extension for the bottom bolts, Might require some weird angles. But, it is possible. And yes I would replace that broken bolt it could cause a leak. And IMO the cometic is a good gasket.

 

[ClevelandDSM]

Dont know about the different gaskets, but you should not have that hard of a time with the bottom bolts. Just make sure you have your size correct, heat it up, use some PB Blaster, and grunt like a body builder

As for the broken manifold bolt already. I would try to remove it and fix the problem while you have easy access to it. I remember reading a thread about the center bolt causing some sort of oil\coolent leak. I remeber the guy that posted had a yellow eclipse , but i cant for the life of me find it by searching.

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Edit
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Found it . http://www.dsmtuners.com/forums/newbie-forum/311376-oil-leak-unexpected-place.html

 

[tkelly27]

Yes, one broken one can cause a leak.

If the turbo is off, socket. If the turbo is in the car and or on the manifold, I like to put an open end wrench between the runners to get to the bottom few. Sometimes takes a pop of a hammer or a jolt with the hands. PBb'laster > WD40 and all others.

 

[Jeff99GS]

Buy yourself a set of racheting wrenches, they work worderfully to get the manifold off!

 

[djalogik]

Buy yourself a set of racheting wrenches, they work worderfully to get the manifold off!

+1
if you get those cheap racheting wrenches like i did they wont fit because they are too fat; it is also a lot easier to take off with wrenches that have a bend at end instead of a flat wrench.

 

[tsi1991awd]

So you guys go in from the top between the runners to remove? It just didn't seem like there was enough space to move the socket wrench. Maybe if I can get behind it all with my ratcheting flat, nice little invention

I know all to well about PB Blaster...works wonders. When I did my fuel filter, the bolts on the bottom battery bracket were rusted tight. Sprayed some PB on it, letit sit for 2 or 3 minutes and they came off way too easy. Lol.

As far as the gasket, I was kind of mad when I didn't see Dejon or JNZ or Extreme PSI carrying the manifold gasket, only the turbo to manifold gasket. Now I have to buy from two different places = more shipping.

 

[DSMunknown]

Regarding the removal of the exhaust studs, I followed Mack's guide. Worked beautifully for me.


http://www.dsmtuners.com/forums/art...217981-how-remove-exhaust-manifold-studs.html

 

[tsi1991awd]

Thanks for the link, good read....I meant just the bolts on top and nuts on bottom though. Sorry for not clarifying more.

 

[Jeff99GS]

Yes I go right from the top through the runners with a good quality Rachet Wrench. I just Swapped My manifold the other day in about 20 minutes! Like Djalogik said get a decent brand of rachet wrenches, cause some cheapo ones have too fat of a head to fit. I have Craftsman wrenches and they fit perfect!

 

[fwdmaster]

By removing that dumb powersteering pump

 

[untouchablecc]

Use a good penetrating catalyst like Pb blaster soak it down over night hit it once more hours before u work on it an it should help.

 

[tsi1991awd]

Yes I go right from the top through the runners with a good quality Rachet Wrench. I just Swapped My manifold the other day in about 20 minutes! Like Djalogik said get a decent brand of rachet wrenches, cause some cheapo ones have too fat of a head to fit. I have Craftsman wrenches and they fit perfect!

Thanks...I do have Craftsman ratcheting wrenches. 8mm all the way to 18mm

 

[mmmmbst]

I always just drop the turbo and get at it with a socket and extention. (just easier, plus i dont have those special wrenches) And to pull that bolt head i would have to agree with the PB Blaster and i would use a vise grips unless it broke off flush with the head, then your going to have to drill and back it out with some easy-outs and hope for no problems. Good luck!

 

[tsi1991awd]

Yea, that one bolt is broken off inside the hole. There's no way to get it without drilling. I've had very little success using the bits that are supposed to back the bolts out. But I guess it wouldn't hurt anything...its stuck inside as it is, so.....

 

[Sp1kE]

I always warm my car up a little when i touch the turbo or manifold bolts.
not too much that it burns to the touch, just enough that you dont wanna touch it for more than a few seconds.
Bolts come out so much easier.

then when you go to install it, let it cool a bit more, so you dont risk the chance of cross threading the more maluable threads.

 

[No_Skillz]

No need to use any fancy pantsy manifold gasket. I'm using a cheap felpro with good results.

Metal gaskets of this sort are more trouble than their worth. They require strict tolerances in terms of cleanliness and flatness to ensure a good seal.

 

[tsi1991awd]

I have a propane torch I can use to heat the bolts up

Also, ill just go to Napa or somewhere and get a cheap gasket....what about the one for the manifold to turbo? Same thing, cheap gasket?

 

[solidviper89]

+99 on the removing ps pump for the right ones, and also for ratcheting wrenches (very handy when working on these cars)

 

[tunernewb92]

O man let me tell you what your in for a really fun time. Ok so I just used a socket with a swivel to get two of the bolts out and just a plain on socket to get the rest out. I replaced all the studs and stuff with bolts. For the bolts that go from the manifold to the turbo, your going to probably break one, if not all of them like me. Home depot sells the exact bolts that you want at 2.56 each. They are m10 by 1.25 by 80 mm long. Hope you have a bolt extractor if you break those bolts. If not and you happen to break one and not the other 3 then your lucky. Get some Permatech Copper RVT sealant and apply liberally to gasket on both sides that is inbetween the manifold and the turbo. You can get a good seal with only 3 bolts if you do happen to break one. If you have any problems pm me and I can help, as I just took this off last night and put it back on in about 2 hours including going to homedepot to get the bolts.
Edit, don't flame me because I didn't extract the bolt that broke guys, believe me, me and 360 glitch tried all we could and its just stuck, but everything is sealed up nice and tight with no exhaust leaks so I'm not to worried about it.

 

[No_Skillz]

what about the one for the manifold to turbo? Same thing, cheap gasket?

No. Get a good SS gasket.

 

[knochgoon24]

I prefer the copper 4 layer gaskets for the exhaust manifold. That with some copper gasket spray and you're golden.

 

[Andy1g]

I'm changing my old 1g EM with a Evo III EM and instead of taking the nut off the stud i accidentally pulled the stud out of the block. I just PBed again and let it sit but any way i can make sure this doesnt happen again? I just threw some lock tight on it and put it back in but if the studs are coming off that easy should i just lock tight the ones that come off for safety or does it not matter?

 

[JusMX141]

Just double-nut the stud and get it back into the block as tight as you can; use red Loctite if necessary but make sure the threads on both the stud and within the hole in the head are both clean and free from oil or the Loctite will not work.

I've pulled many-a-stud out of the head, threads and all, while installing various manifolds on cars in the past.

 

[dsm nuff said]

Do aftermarket turbo manifolds require moving the turbo at all? I was gonna have a local shop throw mine on while they were working on my manifold and they said it would be off by a couple hairs?