Has anyone got any experience of removing and re-attaching the exhaust manifold?

 

Need to drill out a snapped stud on the exhaust manifold where the EGR flexi attaches to it.....

 

Can it come out from the top with inlet removal or is it from the bottom. 

 

Id like to tackle it myself as I know its gonna cost an arm and a testicle for someone to do it in a garage.

 

Thanks all

 

LeezoG

It will come out of the top despite what some have said, you just need to remove everything in the way, a minimalist approach will not yield results.

out the top remove inlet first, 6 allen key style bolts, use a 1/4 ratchet set with a long allan key bit, remove TIP first the horrible Spring clamp on the turbo inlet is a PITA (replace with jubilee)

 

once all that is removed its case of leaning over remove 3 bolts on the down pipe to turbo, remove oil return from block from underneath (oil will drip out so catch it something) and turbo brace to block

 

then start on the exhaust manifold bolts soak them in WD40 couple of hrs before though and use a Hex style socket not multi spline, i did all mine with a 3/8 socket set and extension and a rachet spanner once loose

 

also to help i remove the rear gearbox dogbone mount which allows the engine to rock on the other mounts making removing it a little easier

 

i got to say you are going to a lot of trouble for a snapped stud, just drill it out or puddle weld it like i suggested and throw the EGR away in the bin

 

i can now remove an refit a turbo in about 3hrs just taking it steady, but i've done a fair few of them now, so if tackling for the first time allow 3-4hrs and don't attempt with a ****e cheap socket/tool set

 

these type of allen keys make it alot easier but in can be done with a 1/4" set

http://www.uktools.com/hex-long-10mm-set-rail-p-1221.html?osCsid=7b64701d65965c206bb4d38435d6feb4

silky16v

Thanks for the info Silky, Tools shouldn't be a problem my old man's a retired mechanic and  got too many Snap-on tools, So should be good in that department. 

I do plan on drilling out the old stud, But don't the manifold have to come out for that? or can it be done while still on the vehicle? (would be alot easier) I don't know the 1st thing about welding mate so id have pay someone, And this time of year and a baby on the way, I just cant afford to do that unless the cost is slashed because iv got the manifold ect off myself. and If iv done that may aswell just drill it myself. Im thinking its gonna take me a bit more than 3/4 hrs lol. But at least i got a garage to do it.

 

Love this forum!! 

 

LeezoG

 

sepulchrave

 

Yes bud I gathered its not a minimalist job lol.

I've just changed my turbo after it went pop. As said above will come out the top. Got the front end off, turbo plus all intercooler pipes off in roughly 4 hours and that's my first time. I have my old manifold if you'd rather replace it.