how to remove exhaust manifold

[arbiter]

I am removing the exhaust mani but with no success. The last bolt still stand there. I've read about removing the heat protector of the direction pump but I am unable.

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that's the bastard, here, standing on the mani, as if I was powerless against him.

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I think these two are retaining the heat protector

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I tried to bent it on many ways to put a tool to remove the bolt but... NO WAY

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AS you can see I have started removing a lot of things all around there.. because I can't get that plate out!
BTW, how can I remove the oil dipstick?

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Wait there... I will finish you sooner or later.


I saw a bolt on the inside part on the inner part of the pump bracket.


Using the wrench started to bend it, and the spanner part doenss't fit in a so tinny place.

 

[mindset]

Why not just unbolt the powersteering, then the heat shield?

 

[fwdmaster]

Remove the o2 housing for clearance and use a 12mm flat end wrench,thats how I did mine the first time

 

[saechao04]

I think that ones a 14mm, correct if I'm wrong. I just use a rachet wrench and a breaker bar of some sort without removing anything.

 

[arbiter]

it's a 14, you are right.

What kind of rachet? a flexible one? do you have a picture of yours? (Might sound very stupid question but technical language can be a harm for me, I spend a lot ot time at wikipedia checking for english names of tools)

 

[wishnfor4g63T]

I used the longest wrench i could find. I had to hit Lowes up to do it.

Had to use the closed end to get it loose enough to finger turn. I've taken my manifold off about 6 times in one weekend. so you get used to the tight places however Good Luck with it, i know it's a pita but goto Lowes and buy some tools and whatever you don't need take it back.

 

[saechao04]

I have something like this. http://www.sears.com/shc/s/p_10153_12605_00947419000P and I use the closed end to break it loose until my fingers can do the job. If you move your mouse over the picture it enlarges.

 

[EclipticalGS]

Remove power steering, remove sheild, i dont use the sheild, then use a ratchet, socket, PB blaster. Also, oil dipstick doesnt need to come off, but if you need know, the oil dipstick is jsut pushed into the block via o-ring, and bolted right ontop of the power steering bracket.....errrr.. some bracket around the area. Just look.

 

[arbiter]

I used a bent wrench but finally it's out

 

[twicks69]

Glad you got it out. FYI -- swivel-head gear wrenches are made for things like this.

Check out the SK extra-long swivel-head reversible spline-drive gear wrenches:

SK Hand Tool 89650 - 5 Piece XXL Double Box Locking Flex G-Pro Metric Wrench Set
SK Hand Tool 89650 - 5 Piece XXL Double Box Locking Flex G-Pro Metric Wrench Set

Otherwise, a simple set of metric gear wrenches will do the job:
Amazon.com: Gear Wrench 9602 16-Piece Metric-Set Reversible Combination Ratcheting Wrench: Home Improvement

Or, use the gearwrench adaptor socket attachments with a shortie socket and the gearwrench.
http://www.sears.com/shc/s/p_10153_...odeling&psid=FROOGLE01&sid=IDx20070921x00003a


OR....remove the power steering pump, and bracket, and remove the heat shield for future ease of installation and removal of the manifold. The heat shield is not necessary.

 

[dsmfa9nutter]

A dremel and a small cutoff wheel is the next best tool after the sawzall.

 

[rhodess89]

pb laster the S**T out of it before you try maybe a wait a day or two but soak it down several times and then you can loosen them with no problems.

 

[slow gst]

you can bend your dipstick then bend it back when you are finished

 

[arbiter]

to be honest I did not used any 3 in 1 or wd40, or anything alike.

Just strenght and the right tool for the job ().

Right now I am finishing installing an ebay turbo but I don't have to much time as we are a little bit overwhelmed at the garage.

 

[Fabian]

I'm not meaning to be a douche here or anything like that. But if you dont know how to remove that exhaust manifold I dont think you should be installing your turbo, let alone an EBAY TURBO. You've obviously done absolutely no research on this site or taken its advice in the least bit. There are plenty of times on this site and on Vfaq.com where this has been gone through before. It will really help you to do some searching before just posting up and wasting your time and others.

also just to let you know, if you had ratcheting wrenches it would make getting that last bolt out alot easier for you, I just put a 14mm on that thing and point the wrench towards the valve cover and it always comes off without me having to move anything else or remove that shield.

 

[skatershawn]

..... Ebay turbo?? :/

well you never know... plus i hear that their making them stronger soo who knows!
all i say is PLEASE keep us updated on how the turbo runs and last!
im NOT saying it will give on you, i just want to know someone truely running one and how they run it.. and if it last! the price is hard to get by on those, but i dont know!

Goodluck man!

 

[arbiter]

Ebay turbo:

Well, had some issues with the bolts included in the kit, despite of that, everything is perfect.
removed old mani, bolted turbo to new mani, filled turbo with oil (used mineral 15W30),installed oil return line, filled line with oil, spilled some oil over the turbine and over the compresor for lub.
Installed mani with turbo to engine, bolted on o2 housing (exhaust corner with lambda) to turbo
Later on, had the turbo to slowly rotate to ensure it's lubrication, installed the remaining eye bolts (water and oil IN).
Spent another hour reinstalling all the admission stuff...
charged battery and started the car after refilling water.

Had it 20 minutes at idle, stoped the car, checked for leaks (water exit was leaking), let it cool down (30 minutes, and started again.

I had it on cycles of run 30 at idle at let it cool down for a while. A lot of smoke went out from the exhaust due to manipulation (Normal, grease left by my finger).

Had it a couple of days not over rev from 3.K RPM.
Went over to 5K for a week.
Nowadays running strong. Waiting for my boost gauge to check up regularity, but this morning I had a real fun on our highway as my diesel car is broken down (thank jesus for this journey).

as for now, after 20 days with it, I'm very happy with my car.

 

[jjrock5]

I never knew power steering pumps had a heat shield as well. Anybody have an OEM part number for one for a 2g?

 

[olmytsi]

Swivel socket adapter thingy?

I've always been able to remove it no problem, just did a 16g on a spyder on saturday actually..

 

[Indian]

I always just used a swivel head no probblem.

 

[RyeDawg]

Also when removing the powersteering pump it is a good idea to grind a U in the powersteering bracket directly in front of that exhaust stud. Helps for future assembly/dissassembly. I know people on here know what i mean. search search search.goodluck

 

[Calan]

Also when removing the powersteering pump it is a good idea to grind a U in the powersteering bracket directly in front of that exhaust stud. Helps for future assembly/dissassembly. I know people on here know what i mean. search search search.goodluck

http://www.dsmtuners.com/forums/blo...omplete-rebuild-firewall-forward-part-12.html

4th pic down

 

[ricktb]

I never had to remove my powersteering pump, don't know if my car has that heatshield, doesn't look familiar but I could be mistaken.. just a closed end wrench from above if I remember correctly. Yeah you might break the bolt flush with the surface of the head, but we'll talk about that in your next thread muahahha


ps seems like the manifold has been removed before.. isn't there another bracket that was bolted under that bolt and to the empty thread on the right? I found no purpose for the bracket and ended up tossing it. I guess my car is a 2g so there might be some differences

 

[Long Duk Dong]

Friend of mine who owns several DSM's turned me onto the swivel head "Gear Wrenches". They are not expensive and have become a staple of working on these cars for me.

 

[whyadsm]

Sorry to bring up old thread, but what does people removed before getting to the exhaust manifold? Example: o2 bung, downpipe, and turbo.