What are the chances?

[ktgurl87]

So what are the chances of this 4g63 motor in this '96 not being the original? The odometer reads close to 143-144,000. We got the car used so there's really no telling what's been going on with it.

The reason I am asking is I had to buy another exhaust manifold. Well, it doesn't slide onto the studs... like, at all. It's a little beefier than the old one but I figured that was because it was an aftermarket OE replacement. It's a Dorman manifold if that makes a difference. The holes don't match up. The bottom hole on the passenger side (looking at the car) bottom is like 1/8" off. I talked to my boss and the only different part number he could find was for a '94 automatic. So they ordered one for me so I could see if it matched. I kind of hope it doesn't because i reeeeeally don't wanna pay $200 for it .

Any ideas? Comments? Suggestions? Thanks.

 

[SlowChild3]

I believe all the heads are the same...? I bought an evo manifold for a Tsi I had. Needed alot of grinding to make it fit.

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[ktgurl87]

Yeah see... I don't know exactly what's really interchangeable on these cars. I thought the 1gs were different than 2gs.

 

[EclipticalGS]

thats the wrong manifold, you need to just get a nice used manifold from the classifieds here, go up at the top to Marketplace, then to DSM classifieds, then select 4g63 parts, then type "manifold" , just get a 2G manifold, they are a dime a dozen with all the people around here using tubulars/etc, you can probably pick one up for $40...or less, and just as long as it's crack free, it'll be just fine for you.

 

[ktgurl87]

That's what I figured. But what I ordered was also a 2g manifold. Unless it was boxed wrong. So when it comes I'll just have to enjoy telling my boss that he was wrong

 

[RadDsm]

Can you post up a pic of it?

 

[ktgurl87]

I believe I have a picture. One sec...

Ok... here is the underside of it:

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And here it is in the car:

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Notice the red rags

For all intents and purposes it looks just like the old manifold. EXCEPT for... the holes don't match up

And sorry about the pictures... those are what I have already on the computer and it's dark outside.

Ok sooo... I'm trying to remove the old manifold studs to just see if the holes from the new manifold match up with the holes on the head. I was told that the studs could be a little "heat warped" which could be it won't slide right on. Got the bottom 3 little ones out oh-so-pretty like. The top 3 little ones won't budge, and I broke the bottom passenger side fat stud I bought a set of easy outs for the top little one that had broken, so I guess I could use it to get out the bottom fat one. I am just so ready for this car to be done, but I still need to get quite a bit more for it.

 

[ktgurl87]

so i am such an idiot. the reason the new damn manifold wasn't sliding on was because the point on the bottom was hitting the power steering bracket! few seconds on the grinder fixed that issue and she slid on so pretty. if only i had seen that like, 3 days ago, the car would be atleast mildly put back together instead of sitting half-ass open. stupid stupid stupid!

 

[9!'clipseDOHC]

Glad you got it figured out, we've all done dumb stuff before. So much for telling your boss that he was wrong though. But at least now you can mark this thread as resolved (it's under thread tools).

For anyone else reading this who may be looking for a manifold, I second the classifieds; I got my 2g manifold for $40 shipped.

 

[2GbTalonGuy]

Glad you got it figured out, we've all done dumb stuff before. So much for telling your boss that he was wrong though. But at least now you can mark this thread as resolved (it's under thread tools).

For anyone else reading this who may be looking for a manifold, I second the classifieds; I got my 2g manifold for $40 shipped.

Agreed, the classifieds on this site rules. Great people sealling good stuff for great prices.

 

[LiquidX]

For anyone else and including you katie, there is a special tool you can get that will help with stud installation and removal.

Sears: Appliances, Tools, Electronics, Apparel and more from Craftsman, Kenmore, Diehard and other Leading Brands

There are more styles than just the one I listed but it makes things easier than trying to do a double nut technique.

 

[ktgurl87]

i ended up getting a stud remover and got the bottom three out no problems.. the top three little ones will not budge so i figured i'd leave them be . not tryin to break anymore than i already have.

 

[LiquidX]

Just remember that there is a chance that these studs have never been touched before. Being a 96 that's 14 years worth of heat cycling. It would be a smart decision to have just replaced all of them with new studs regardless if they broke or not just so you have piece of mind for the next time around.

 

[19Eclipse90]

^^^Agreed. Regardless of whether you replace them all or not, there is one thing I cannot stress enough for the nuts:

ANTISEIZE!!​

When you need to remove the manifold again, you'll be very glad you did. I think some members frown on that, but IMO, it beats having to drill out those broken studs.

 

[LiquidX]

I wouldn't use anti seize on the head side of the stud but the nut size is great to use it on. It'll just keep the two metals from oxidizing together for what ever reasons but if it's on the head side then taking a nut off may pull the stud out as well.

 

[19Eclipse90]

...there is one thing I cannot stress enough for the nuts:

Agreed again. If you don't use it on the nuts, the studs will break one time or another. Definitely not on the head side, though; I probably should have made that clear.

 

[jabrow87]

what about the crack in the first pic where the turbo bolts up?

 

[SlowChild3]

so i am such an idiot. the reason the new damn manifold wasn't sliding on was because the point on the bottom was hitting the power steering bracket! few seconds on the grinder fixed that issue and she slid on so pretty. if only i had seen that like, 3 days ago, the car would be atleast mildly put back together instead of sitting half-ass open. stupid stupid stupid!

Yup, that's the same place I had to grind.

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[ktgurl87]

i don't see a crack in the first picture? and why not on the head side too? i definitely am gonna use anti-seize when all is said and done, but what would happen if you put anti-seize on the head side?