crack in front manifold

[ochten]

have a large crack in the front manifold. can i replace it with the engine in place?

is welding ok or should i buy a new one

[nawarne]

Jan, just seen this post.

For me, I'd say do a weld repair....the crack is barely visible.
Would be a fairly quick and easy thing to do? Remember to protect the ECU.

Nick

[quint22cp]

I can say from very recent experience that on a early Tuscan it isn't possible to remove just the front manifold. The rear one prevents its removal. To remove both manifolds with the engine in situ is a nightmare I gave up as it was too difficult to access the manifold bolts.

[ochten]

Welded the Manifold. Seems to be Ok now but during the MOT last week if failed.
Small leaks before the Cat makes the Co2 sensor/ECU very unhappy! Bought a 2 tons Crane to remove the Engine (again , is the 3rd time now)

[PhilF329]

What a shame - hopefully third time lucky!

[mk1fan]

I was given a tip to cut down an allen key to access the rear cap heads screws. Faffy job though.

While the manifolds are off and repaired, how about ceramic coating?

[glow worm]

X-Works removed my manifolds (for ceramic coating) on both my Tuscan convertible and my Sag without taking the engine out . Heath just complained about taking the skin off his knuckles .

[mk1fan]

That's a harsh thing to do to the apprentice.

[PixelpeepZ4]

Did you not learn anything from Fast & Furious ?

too much NOS! Danger to manifold !

[ochten]

What a work for a crack! Engine out that is fine. But now are some bolts seized and very difficult to reach! W hat next?

Cut the manifolds off to clear?

[ochten]

[mk1fan]

Are they stainless bolts? Someone forgot the copperslip.

Allen socket on a couple of extensions?

Some gentle heat?

[Sagi Badger]

Done it twice engine in and a few times on the bench. You need acres or patience and it helps if you soak them well. I haven't tried freezing but it gets good reports. I have a monster selection of hex bits, all makes including some imperial ones that are ground down to be extra tight. there is one I think that only a ball end will get, leave this till last so you can jiggle-ize the manifold to help it loosen off. I have a 6mm ring spanner with a stub of cut down allen key in it, loctite retainer or a wedge of tape will hold it in.

The bolts are normal 12.9 cap heads, not stainless. Stainless bolts are a mare, you only get one chance. Don't be tempted to chisel these round, there is next to bugger all meat around them into the port and I have seen them cracked from thread hole into the port. I never over tighten them, palm ratchet only.

J