Manifold replace on 2.9 (exhaust)

[gadgit]

Got me new stainless down pipes from Leebee, and went and got some nice stainless bolts with Allen heads. After I managed to work out how to get the manifolds back on, i can't get the bolts in on several holes and its driving me mad. Problem is which way to do the job as well. I presume you fit the manifolds first, leaving them loose and jiggle the down pipes in.

What have you lot done about the bolts. I've found that its nearly impossible to fit studs in first and then try to put the manifolds on. which is the best way to do this job!

thanks.

gadgit.

[SMiles]

Unfortunately the way to fit these seems to be to take off the entire exhaust. Fit the manifolds first , then doawn pipes and finally rest of exhaust. I too had trouble getting the manifolds on. What actually happend was I put the manifold sort of in position, fitted the down tube, then put the first bolt in (at the bulkhead end) then with a great deal of jiggery pokery and a sixteen stone mate hanging off the down tube managed to get the rest of the bolts in.

I had no skin on my knuckles for weeks but the car sounded great.

[PeterC]

Another usefull tip or two, but first a question. Are you certain the new studs/bolts you are using do exactly match the thread in the heads - diameter, pitch etc.? Try matching the an old bolt to a new one, they should mesh exactly.

Use the new one piece manifold gasket as a template to confirm that the manifold is accurately made and all bolt holes line up as they should. Some minor tweaking might help here.

Go to a good ironmonger or tool supplier and buy yourself a thread tap to clean out the threads on the cylinder heads. Take a bolt (and a matching nut) along with you for the purpose of identifying the right one. (Mines at home so I cannot tell you what thread it is -it cost me £4.50 to buy)
Clean out the threads using the tap and oil as a lubricant. Do it gently so as not to break the tap which is hardened brittle steel.

You will find that if you follow these tips, the bolts can simply be tightened with the fingers and then simply finished with a small socket or suitable spanner.

[gadgit]

What a pain in the ar*e getting these manifolds on!

first tried to put studs in and then put the manifolds on, no good, they wont go on with the studs in.

found as previus owners, you have to hold up the manifolds in position and screww the studs in through the manifold holes. Now, the last bu**er is so close to the curve on the pipe that you can't get the nut on!

so, you have to screw the stud in to far and start the nut and then turn the stud back through the nut to get enough thread on the nut. What a performance! oh and don't forget while your doing the finishing touch, you will need some exhaust jointing paste on the gaskets to make a good seal. ARE! of course, the paste is going off while your taking all the skin off your fingers rushing to get everything on in a hot garage.

I'm now recovered enough to go and do the other side, and at least I know all you other lot have gone through the same process (all swearing at TVR)

all the best.

gadget.