Exhaust Manifold replacement recommendations!
All,
My 230GE has had a small exhaust blow from no.4 cyclinder exhaust gasket for a while. It is an advisory only in the MOT.
Its an aluminium head mated to an iron M102 engine block, and has likely never been removed in 35 years.
Obviously, the manifold studs will not come out easily, if at all. The nuts holding the manifold tight to the block on these studs may free up, or they may snap the studs! Probably, 7 will free up and the 8th will snap (Murphy's law).
A snapped stud will mean the head has to come off and a big job (I can see where my mind is going)
Any suggestions?
Asking a good garage to do this is likely to result in a lot of caveats and potentially a complete nightmare (imo)
Mike did this on mine the end of last year and was a complete pig of a job!
3 garages had looked at it locally and refused to tackle it
It took 2 of use 7 hours in the end
Over half the nuts would not come off and the others had to be split, chiselled and belt sanded
No studs snapped but again over half were detroyed in the process along with the thick washers
I had new gaskets, nuts, washers and studs and he replaced them all
Access was dire
We had to remove the right engine mount and bracket and jack the engine up for access along with removing other things
And mine is a low miles 1990 ex Japan that has barely seen use on UK winter roads
Head off is a bit extreme even for a snapped stud...
Make sure you check the cast manifold for trueness when off as they do warp and crack and may need skimming
And make sure you get the lastest modified gaskets...a few variations but should be 3 of one with 2 holes and a single with 3 holes depending on engine number
If its the F plate of yours they are...
A102 142 14 80 x3 Manifold Gasket
A102 142 15 80 x1 Manifold Gasket
A102 990 04 05 x9 Manifold Stud
N999901 008005 x9 Manifold Nut
A116 990 14 40 x9 Manifold Washer
A000 990 25 52 x4 Special Nuts for the Front Pipe Bolts
The Front Pipe Bolts should be standard fare...
I guess it's a job you could tackle yourself if you don't need it for a week! Having the right tools and space is key as always
And space is why most garages don't want to take it on.... they don;t want a dead vehcile to push around for a week if it goes pear shaped !!
Best of luck to you mate.
It was easy for me as I had the head off and put a wee weld on the top off the nuts becuse the studs were stuck.
But defintely get the manifold skimmed and new gaskets.
Take your time you will do it :)
Give everything a through soak dosing with Plus Gas, at least several times in advance
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