Series 3 Exhaust Manifold 2.25 Petrol

Hopper78 · Aug 13, 2019

Ended up with sheared down pipe studs during exhaust removal. I've removed the manifold - is it worth replacing with a new replacement or just taking them to a machine shop for drilling out and reusing the existing one?

Also, are there any other maintenance jobs worth doing with the exhaust manifold removed that's easier access wise?

Cheers

Hicap phill · Aug 13, 2019

Drill out & replace. Make sure you get the correct size studs. There are 2 diameters.

John S · Aug 13, 2019

X2 if you’ve got a die set it’s definitely worth it. A new manifold is expensive. Have you got the brass set screws out of the manifold exhaust? Worth refitting them with the manifold out they are cheap to buy. With the manifold out you’ve got good access to the starter motor. In saying that unless you think it needs attention and if it’s working fine I wouldn’t touch it. Apart from that you’ve got great access for probably a long overdue clean up of the block.

Colthebrummie · Aug 14, 2019

I think some folk have just drilled out a broken stud and fitted a nut and bolt. I don't know how much a replacement manifold is and I don't know how much a machine shop would charge to fix the old one either, so I couldn't comment on that. Does the inlet manifold need to come off to remove the exhaust manifold?

Col

Hicap phill · Aug 14, 2019

@Colthebrummie It can be a tight fit for bolt head on the manifold. Use Allen key set. Screws.
I used the 2.5 diesel studs on the petrol so need also to drill out the exhaust flange. This enables me to use 6mm set screws for emergency road side repairs.

Hopper78 · Aug 14, 2019

Thanks for the advice - going to see how much it is to drill out and retap. Have bought replacement gasket, studs, nuts etc. for both inlet and exhaust manifold - the old ones aren't in the best of shape.

rob1miles · Aug 14, 2019

Drill and re-tap is a nice repair, but its hard to get right, if it goes wrong a plain hole and set screws or bolts with half the head ground off makes for a good fix as it means you can always saw the bolts if it gets seized. I do a lot of work in the offshore industry and the trend is to nuts and bolts not studs as they are much easier to fix in the field; angle grinder plus new nut and bolt is much eaiser than drill centreing, drill size, picking threads out and retapping plus getting stud in.

Bobsticle · Aug 18, 2019

I have bolts in my diesel. I just touched the manifold with a grinder so I could seat the bolt heads. No issues since. Oh and I used stainless bolts.
The hard bit is getting the manifold back on if the engine studs came out with the nuts. They don’t seem to line up easily.

Simon Perks · Aug 19, 2019

I had this .. drill out and replace with a nut and bolt ... job done

Series 3 Exhaust Manifold 2.25 Petrol

Hopper78

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Hicap phill

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John S

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Colthebrummie

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Hicap phill

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Hopper78

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rob1miles

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Bobsticle

De Villes Advocaat

Simon Perks

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