removing/replacing exhaust manifold/downpipe-flexi

8 years 2 months ago - 8 years 2 months ago #23250 by broon
Its easier if you have ramps and just park with rear in the air. Otherwise get it up on axle stands to allow room to manoeuvre underneath.

Ok, so remove the engine access cover and this is what you see







remove screw/bolt (was bolt on old car...on this one a screw) for top of heatshield





There is also a bolt at bottom heatshield but no pics as mine didn't have one

Now remove the 3rd heat shield bolt..with spacer...this is 13 mm




5 bolts to remove .....15 mm socket








Now remove the heatshield

Looking from under the car , this is looking up through downpipe to manifold from ground




and a closer shot, looking at manifold/downpipe flange (6 stud manifold)




Now remove bolts form manifold/downpipe flange...15 mm. Use an extension bar to reach bolts. Remove 6 bolts





Now remove cat/downpipe bolts. Mine already had cat saver bolts, so is easy....you may have problems if this is first time!1




Now you need to remove the downpipe from the rubber mount...this is made easier by spraying with WD40 or other lubricant first!




disconnect oxygen sensor plug and then remove the downpipe from car...may take some jiggling.

Attach new gasket to downpipe/manifold flange




also new gasket (and firegum style paste to make a good seal to cat/downpipe flange)

DONT add gum/paste etc to manifold/downpipe gasket as it can damage o2 sensor!!

and ..........reverse!

(attach new or old oxygen sensor BEFORE refitting downpipe)

exhaust manifold bolts = 45 nM....downipe/manifold flange bolts = 50 nM...cat/downpipe bolts ...50 nM

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8 years 2 months ago #23273 by David Aiketgate
Nice one , Broon!:thumbsup:

David
:shrug:

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8 years 2 months ago #23726 by Rich in Vancouver
That's an impressive how-to.
It's a keeper!
As an alternative to the firegum I have used a product by Permatex
called Copper Hi-Temp Form A Gasket.
I have used it on my TR instead of an exhaust manifold gasket, and it has
stood up well for years.
Looks like those cat nuts are worth their weight in sweat!

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8 years 2 months ago #23761 by bryan young

Rich in Vancouver wrote: That's an impressive how-to.
It's a keeper!
As an alternative to the firegum I have used a product by Permatex
called Copper Hi-Temp Form A Gasket.
I have used it on my TR instead of an exhaust manifold gasket, and it has
stood up well for years.
Looks like those cat nuts are worth their weight in sweat!


YES, the cat saver "nuts" are worth their weight in gold. and not very expensive either :whistle: :whistle:

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