Exhaust manifold 2,5D defect

[drivetheglobe]

Hi,

Have a crack in my exhaust manifold. Mk5 1997 / 101PS / 2,5D. (914F 9430 AA)
What needs to be considered when I change it ? Some screws/nuts that I will damage - look all like beeing 21 Years

Thanks a lot

[jamie182]

i have taken a few off and normally they will come out pretty easy. the Di engines have a cast iron head so normally don't give issues just go steady. ( i have run them out in the past with a air gun and not had issues)

[Realist]

My manifold split as well purchased a new one but at a cost of £280.00, didn’t fancy trying to weld cast and take the risk of it failing.

Plus two bolts snapped so it’s a drill job as well for me.

[MinorMatt]

If you crack the bolts off when the engine is hot... the chance of snapping is much reduced

[blizard]

And soak it with penetrating oil, try to fasten a little and then loosen the nut.
If you force it, it will break certainly.
I struggled weeks to get the 3th injector out, penetrating oil and a lot of heat got it finally out.
This oil is also avalable as iced versions.. I use Innotec.

[V184]

Fit the correct studs on the manifold & replace the bolts that mount it to the engine

[drivetheglobe]

Thanks a lot for the hints! Will get a new one and maybe some bolts...

[drivetheglobe]

Hi,
After driving home from long Easter Weekend, I immediately tried to loosen some screws on the manifold when the engine was warm.
Managed to open one... the others are too hard reach before de-mounting AGR and whatsoever there or did not move - or both.

And: I have screws and not nuts and bolts...
Still make them warm or better cool to get them out ? Have some 7 left plus some from the AGR/Exhaust etc...

[drivetheglobe]

I could loosen 6, one is broken and one is still in .
Clearly the broken and hard one are those at the very end - so hard to reach....

I ve seen also that I cannot unscrew the manifold from the turbo as the screws are not reachable.
Do I have to unmount the complet turbo plus the short part of the exhaust till it goes to the "normal" exhaust pipe?
Seems ugl, unmount the oil pipes etc...
This is the only way?

br

[V184]

Remove manifold/turbo as one, refit the same

[drivetheglobe]

Thanks, in the meantime Nr 7 is removed - so only one broken, will try to remove as you said and then weld a nut on it as its broken outside.
Think it was damaged before as it was broken easily, more easy than the other to get them out.

Have read in my book that they put some paste in - should I and which ?

[V184]

Thanks, in the meantime Nr 7 is removed - so only one broken, will try to remove as you said and then weld a nut on it as its broken outside.
Think it was damaged before as it was broken easily, more easy than the other to get them out.

Have read in my book that they put some paste in - should I and which ?

wouldnt hurt ? change all the bolts & dont us a gasket between the manifold & cylinder head

[drivetheglobe]

Hi,

Here how it went...

20190501_102257_kl.jpg

After welding it - it went out like it was butter...

Here the old manifold

20190503_211736_kl.jpg

Separation from the turbo is quite impossible as the nuts are not reachable properly. So better flex the nuts off - I did the mistake to flex also the bolt, so they were gone also...


And here after fitting together with the turba after the friendly man from the ford garage provided some new bolts and nuts

20190503_211542_kl.jpg

[blizard]

Ford guys are always frienldy
Turbo seals/bearings ok? you have it off now, easy to check

[edessaios]

i had the same problem with the same crack. I managed to weld the manifold twice, and cut new gaskets by my own. Untin today, no problems at all. The manifold is really expensiveto buy it brand new... Did you managed to fit an intercooler?
this is the next step i want to do!

Cheers