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Exhaust Manifold

bgold87

Probationary Member
24
4
Nov 20, 2019
Louisville, Kentucky
What's up guys, needed to replace my turbo cooling line and when I took the manifold off (turbo on) most of the studs came out with it so removal was cake.

Put a new stud kit on and trying to re-install that manifold with studs on this time and have tried everything and I can get the left side to drop on, but the right side won't line up. Is there a trick or do I need to somehow lower/remove the turbo for more room to work?
 

XC92

Proven Member
670
91
Jul 22, 2020
Queens, New_York
You're lucky! I just derusted and painted the upper manifold cover and engine hanger on my 1G and noticed that 2 of top studs were missing the nut, which makes me wonder what's keeping it on other than the remaining nut. Scary. Sorry, can't help you with this issue but I'm sure that one of the old pros will weigh in with useful advice. Did the manifold fit without studs in? Maybe it's the wrong kit for your engine and manifold? Just guessing. Good luck.
 

TK's9d2TSi

Supporting Member
4,641
1,899
Sep 11, 2017
Cincinnati, Ohio
It’s a little tight but should be able to get it on. Barely put on one side and then tap the manifold on the other side. If you still can’t get it on, enlarge the hole(s) on the manifold. Not too much obviously.

I have an fp manifold and had to trim the p/s bracket to make it easier when I pull the manifold. I don’t think stock manifold was an issue for me.

What manifold do you have?
 
Last edited:

Mech Addict

Supporting Member
474
173
Jun 9, 2019
Jackson, Wyoming
Are you sure you are putting the gasket on the right way? It only goes one way. Did you remove the cooling fans? I recently took my turbo-manifold off in one piece, swapped the studs, and it went back on without much trouble.(once I figured that the gasket only goes one way) I already had the fans out, too. The one nut on the far right side( toward the timing side) was tough to get a socket on.
 

XC92

Proven Member
670
91
Jul 22, 2020
Queens, New_York
If some of the studs are missing nuts, does that usually mean that the tip of the stud they were on broke off, or that just the nut unthreaded itself off, perhaps due to vibrations?
 

XC92

Proven Member
670
91
Jul 22, 2020
Queens, New_York
It's hard to tell. There might be just enough length projecting to allow a nut to be tightened onto it, or not. I'm guessing that they snapped off, perhaps during a repair years ago, although I don't recall ever having had exhaust, turbo or engine work done.

I was going to remove and derust and paint the manifold at some point so I'll replace the studs then. I'd rather not do it now because it's going to be a pain to extract the ones w/o nuts and I'd rather pass inspection first. And extraction is even harder on cold days.

The one stud I removed came out entirely and not just the end nut. Is that normal?
 
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