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SIXTT
Original Poster
479 posts
53 months
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I need a bit of help folks Although not that apparent when I picked the car up there was clearly a leak in the exhaust somewhere. This was amplified when I took all the old carpets out and bass speakers in the rear bulkhead (leaving 4 big holes into the boot space). I have taken the full exhaust off back to the manifolds and herein lies the problem. The exhaust on the offside from the manifold is badly corroded at its end and provides no seat for the exhaust side joint. The joint was caked up with a variety of crap (and somehow passed the MOT) but its not working. Plus I want the car right. I have managed to remove the 8 offisde exhaust manifold bolts and the manifold is now loose. However it doesnt look like it will come out ?? Is this an engine out job or has anyone manged to get one out by some means. Will removing the starter motor help? If it wont come off what is the best way to repair the exhaust? I was looking to cutting it back and sleeving it - has anyone any ideas or recommendations to buy a ready made sleeve? If I can get it off I can easily weld it, but in situ it looks like a nightmare to weld as space is very tight. It looks like its been repaired before. Photo of corroded end.  Working space in situ is very limited  Thank you John
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JMF894
1,466 posts
24 months
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I havent done this myself but i do recall from other posts that the engine needs to be tilted to one side in order remove one of the manifolds. Undoing the engine mount and jacking it up should do the trick i seem to remember. It may well be the offside.
Hope this helps
Jimbo
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ralph350i
627 posts
16 months
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Pig of a job mate, but what i did was jack the engine up and remove the starter and engine mount and you should be able to pull it though the engine bay, good luck
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SIXTT
Original Poster
479 posts
53 months
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oh joy ... what do you have to disconnect engine wise (other than the mount and starter) . I will probably take the starter off anyway and clean it (although it looks new).
The cars just been in to HHC and they think the intake manifold is leaking also - looks like Ill be busy for a while.
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SLB
130 posts
110 months
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I've had to remove manifolds a couple of times from below the car. I seem to remember that there is a squeeze in the pipework and it's around this area that you can't easily get it between the chassis and the clutch housing. I remember levering it a bit with a bar and it popped out, and to get one back on used a car jack but it didn't damage it at all. I don't remember having to remove the starter. Don't cover them in the thermo wrap as I did, a brand new set of manifolds were destroyed in 2k miles due to glowing red hot underneath and just disintegrating.
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barrington
865 posts
100 months
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i repaired a manifold by going to an exhaust shop and bought a straight piece of exhaust with the flange on the pipe needs to have an outside diameter that matches the internal diameter of the manifold i cut the tube about 100mm long put some paste around it and pushed it in the end of the manifold it was a tight fit but i put a clamp on and then refitted exhaust only cost me about £30 lot cheaper than new manifold and less agro than removing manifold and worked purfect
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ralph350i
627 posts
16 months
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SIXTT said: oh joy ... what do you have to disconnect engine wise (other than the mount and starter) . I will probably take the starter off anyway and clean it (although it looks new).
The cars just been in to HHC and they think the intake manifold is leaking also - looks like Ill be busy for a while. Hi Mate Nothing else apart from the plug leads, when you put it back you will find the rear section hits the chassis and gearbox, what i did was jack it up which pops it into place and make sure when you replace, put the 2nd nut in from the front off the engine first as it needs room to be fitted, good luck
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