E30 Exhaust Manifold Gasket

[tejawxyz]

Hello all,

I'm trying to remove the exhaust manifold off my E30 touring (M20) to change the gasket as it is blowing. I've somehow managed to get all the nuts off, even that impossible one that is right behind 4th cylinder. Then I soaked the mating areas with penetrating fluid for a couple of hours.

I've tried to pull the manifold off with no luck It doesnt even wiggle. Any suggestions?

Thanks in advance

[daimlerman]

If you have removed all of the nuts without breaking a stud you have done well!
The usual cause of an exhaust blow from the manifold/head join is a snapped stud caused by the manifold warping.

I can only think that the studs have rusted to the manifold,something that I have not heard of before....you have removed the exhaust front pipe?

[tejawxyz]

Yea, I am surprised too, I guess the trick is to soak it with penetrating fluid in advance and get to it the next day.

As far as the manifold itself, its still stuck. I havent removed the front exhaust pipe, are you talking about the downpipe? If so No.

[daimlerman]

If you unbolt the down pipe from the manifold,you may be able to use a suitable implement up the manifold's hole to give you more leverage...

[Brianmoooore]

How many nuts have you removed?
When you do get it off - all new studs and new nuts are strongly recommended.

[tejawxyz]

I've managed to remove all the nuts. I stuck a pry bar between cylinder 4 and 5 to pry the manifold slightly which worked but its stuck against the Steering Shaft..

I will have a go removing it from the downpipe tomorrow. It doesnt look promising the way it looks almost welded due to the heat! And yes, my new studs and nuts are ready with anti seize copper grease

[pacerpete]

If you haven't undone the downpipe from the manifold and the downpipe from the gearbox(assuming the bracket is not MIA) the manifold will NOT be going anywhere fast !

[tejawxyz]

Yupp, I've undone the bracket to the gearbox, and the nuts to the downpipe. That was a faff! Finally managed to separate it. Thanks everyone for the help.

I'm going to take this opportunity to replace all gaskets, studs and nuts, including the ones for downpipe. Fingers crossed the studs wont snap during removal.

[tejawxyz]

I've put everything back together. The rough exhaust sound is till there!

Has anyone had experience with the exhaust manifold leaking elsewhere? Apart from the gasket? I did not get the manifold skimmed, would that be a common problem? Are leaks common?

Thanks

[daimlerman]

The usual cause of an exhaust blow from the manifold/head join is a snapped stud caused by the manifold warping.

[Brianmoooore]

Apart from the gasket? I did not get the manifold skimmed

You should have checked the manifold against a straight edge to see if it needed skimming.