Exhaust Gasket time !

[peterc67]

Hi has any one exerience of replacing blowing exhaust gasket on 2.8 cologne in situ...looks as if very very tight once the dreaded bolts / nuts are
removed? thxs...dreading this an advise welocme...

[MJG280]

The two manifolds are different but the good news is that they are both as awkward as each other to get off. Not really as long as you have a half decent socket set,I found it easy enough

To clean up the surfaces I found it best to separate the manifold from the system You will need to undo the bolts from underneath. You will need two socket extenders.
There is no gasket from manifold to exhaust just a large ring. I had to drill out the studs as they had almost corroded away. Just drilled through and replaced with a bolt. Works ok.

My manifold had a split and was brazed. (It passed the mot ok as no-one noticed the extra noise). I machined the surface with an angle grinder. It has never leaked since

I was lucky as the stuck on nuts just unscrewed the studs in the head. You will probably need some new studs and nuts

[peterc67]

Thanks for the info..all done with the engine in situ ?

[MJG280]

Yes

[Comadis]

Yes, too!! easy as long as the nuts will loosen without shearing-off the studs. (murphy´s law: at least the last one will shear-off)

[grahamw48]

Not if soaked in penetrating oil for long enough.

[peterc67]

Thanks for all the advise will let you know how get on...

[peterc67]

Soaked with fluid couple days and had an initial go....They Aint Moving !! think I need some quality sockets before attempting again any advise ? (2.8i cologne lump)...Any one used the Irwin http://cgi.ebay.co.uk/Irwin-Bolt-Grip-Fastener-Rem... ??? Any advise appreciated dont want to end up with a complete head off job !!

[grahamw48]

Try jarring them first with sharp taps.
Have another go at loosening, tap hard again and if nothing is giving (don't force them)...more penetrating fluid. A couple of days patience may save a lot of hassle.
Always worked for me. Good luck.

[Comadis]

what fluid you soaked them?


dont answer WD40...

[grahamw48]

PENETRATING FLUID...as I wrote.

[peterc67]

Took Grahams advice and first 3 loose already
...more Penetrating Fluid patience is the order of the day..biggest problem has been getting correct spanner size the 17mm I got is just to big and rounding 16mm to tight,,,will get the B*******s off somehow!!

[grahamw48]

Slowly slowly catchee monkey.

[Barkychoc]

Use some plus gas if you have't already - no other penetrating fluid comes close IMHO

[peterc67]

Got 5 of the 8 moving now another question...can u remove the nearside manifold in situ? looks very tight (the studs will still be in and looks as if it will not clear the body/frame..has any one done succesfully?

[grahamw48]

Can you lever the engine over with a big bar or something...even take the engine mount nuts off that side ?

[peterc67]

Yes good point..may give just enough I hope!

[peterc67]

Took 2 weekends but got all off safely thanks to advise..New to this im afraid reffitting ? do u use anything to help seal the new gaskets on manifolds? Copper Grease on studs when reasembling ? Sealing ring between manifold/top of exhuast clean and re use or are they available new,,dont want to do this to often...

[grahamw48]

Look at the Hermetite(sp?) sealants in Halfrauds ?

Well done by the way.