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The exhaust manifold saga continues for me. Back in December I discovered the car needed replacement of the exhaust manifold studs. My wife took the car to an indie I've used in the past. He replaced the manifold gasket, warped manifold, and the studs with bolts. He also replaced the studs in the turbo with bolts. Now I know why. It makes the job go MUCH FASTER. Replacing the studs in the turbo with bolts does away with the need to drop the turbo to facilitate sliding the manifold off its studs.
The WIS goes through a HUGE song and dance to drop the turbo. They start by draining coolant, and taking out the fan unit. Is that really necessary?
I've now discovered the center bolt in the exhaust manifold is broken. I'm annoyed. The bolts and new manifold gasket don't even have 9,000 miles on them! I take it back to the indie and he'll just put more bolts back in that will break again!
As Swedecar once stated the exhaust manifold is a Chinese box puzzle. With studs perpendicular to each other in the head and turbo, the latter has to move - unless bolts are used.
The WIS procedure is massive. More than I care to do. From what it looks like I can remove the engine yoke and MAF, release the serp belt, then loosen the power steering pump and move it. Apparently I can also loosen the intake tube on the turbo and move it toward the radiator to gain access to that pesky #1 manifold bolt. All the others are reasonably accessible. Has anyone else done it this way?
Since the indie used bolts, the manifold will be easy to remove without moving the turbo. Remove bolts and just slide the manifold forward and out. I'll hope that the broken center bolt didn't break flush or worse is recessed.
My plan on re-installation is to use ARP studs and nuts in the head:
https://www.kronaperformance.com/product-page/arp-stainless-steel-exhaust-manifold-studs Previous posters have had good luck with them.
I'll use M8 bolts in the Turbo to ease installation. Only my choice is to use fasteners from Stage 8: https://www.stage8.com/product/3902-turbo-bolt-kit-8mm/
Has anyone else used Stage 8 fasteners? They look like just the ticket to prevent loosening and blown turbo gaskets. Not cheap, but you get what you pay for.
_______________________________________
'03 Aero 5Spd, Krona, 290 bhp (son's)
Sold:
'04 Aero Sport Kombi, Sport Tek, BSR
'03 Linear 5 spd. Krona Mods, 350 bhp
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