V8 Exhaust Manifolds

[Guest modifiedv8engines]

Hi All,

Anyone out there managed to remove the exhust manifolds with the engine in situ ?

I have a manifold leak due to broken stud, missing nuts which is looking like a removal job and new gasket. I dont currently have the facilities for engine removal so wondered if anyone has acheived this task.

Any advise would be useful before I get started

Cheers

Paul

[mike_sekinger]

Hi Paul,

I think that you´re out of luck regarding removal of the manifold in situ. I´ve never heard of anyone managing this.

I really don´t see it plausible to jack the engine sufficiently from underneath, to make access possible. Even if you removed the sidewalls, the engine would have to be unfeasibly high to manage it.

Can you not borrow a lift from someone or even buy one?

Cheers,

Mike S

[Guest modifiedv8engines]

Hi Mike

I have a seeley/machine mart type engine crane but it looks as though the spoiler, tailgate and various other ancilleries will need to be removed before the engine can be removed.

Although it would mean working on my back with the car jacked up I was wondering if it was possible to say remove cat pipe, turbo and the extra space available may provide enough space to get at the manifold bolts and remove the manifold ?

Cheers

Paul

[mike_sekinger]

Hi Paul,

As I say, I´m pretty damn sure that you will not have the sufficient clearance you need to gain access remove the manifold in situ.

I´ve changed the turbos laying on my back and that was horrendous enough. I think that you´ll find it very difficult/impractical to remove the LH exhaust manifold heat shield. From memory, this required the removal of the AC compressor... and even then you will not be able to access the nuts.

If by some magic ´Houdini-like´ method you do manage it, please let us know the tricks.

Cheers,

Mike S

[superdavelotus]

Hi Paul,

I can get your engine removed and put back in for £600. Manifolds then shouldn't take too much work. You can choose to do this work yourself and get garage to do it. They can also do the work in a quick turn around. No nonsense and waiting for weeks/ months to get your car back. If you get stuck then PM and I'll give you their number.

They currently have my engine out of my HC turbo in less than a day with gearbox off, manifold off, water pump off etc. it should be nearly ready now.

Regards,

David Walters

[Guest modifiedv8engines]

Cheers Dave

If you could let me know where they are I will consider it. I have the factory 5 miles in one directiopn and Stratton about 10 miles in the other. May be a good time to also check cam belts, fuel tanks and all the other jobs that are best done with engine out.

Cheers

Paul

[Guest modifiedv8engines]

Update :

Just spoken with a very helpful and knowledgable guy at PNM Eng. who advises that the exhaust manifolds can be removed with the engine in situ.

Of course, as PNM Eng point out, if work is required which may be say removing a broken stud or similar from the front end on of the engine, then access would be very restricted and drilling/tapping would not be possible. Given that a manifold gasket has blown due to say stud nuts loosening and causing the gasket to blow then removal of the manifold would be possible ...........Hopefuly get started on this fairly soon so will post my findings here for others who may be contemplating a simliar fix

If anyone has anything useful to add in terms of what other potential problems I might encounter then please post a response

Cheers

Paul

[mike_sekinger]

Hi Paul,

Very interesting - I´m looking forward to hearing about your experiences.

Mike S

[superdavelotus]

Hi Paul,

That's not right. I visit PNM most days and they cannot take manifolds off without taking the engine out. They have a V8 in their workshop as we speak with the same problem and the engine has had to come out. It's currently sitting on the floor waiting to go back in. Don't be fooled.

I will post a picture if you don't believe me?

Even with the engine out it's not easy.

Oh, turn around isn't quick there. I wanted my manifold doing on my HC Turbo. They were taking too long so I took it somewhere else. I am glad to say it's done already

If you want to discuss taking your engine out any further then drop me an email dave@acsdesign.org I may be able to get price down a tad.

David

[Guest modifiedv8engines]

Hi Dave

As the guy @ PNM said/mentioned, that particular car also needed cam belts, both exhaust removing + some other jobs so engine removal was the best option. It was also mentioned that V8 engine removal ( if required) is easier than removing the engine from a 4 cylinder esprit since there is only one ECU plug, and most of the ancilleries are attached to the engine.

I have also spoken with SJ SportCars and they reckon its possible but there again if both side want doing then its easier to remove the engine and carry out belt checks etc whilst on the bench. Either way its a horrible job but the possibilities are :

Engine Removal :

Remove exhust system ( had this off to replace cats already so bolts should be okay)

Pop out drive shafts

undo engine mountings + gearbox mountings

undo gear linkage

remove fuel, sensors pipes and coolant pipes

Remove spoiler

Jack up tail gate

remove engine bay side walls

remove rear floor and engine covers etc.

doubtful whether my engine crane would have sufficient reach without making up leg extensions so maybe a gantry

Even if engine removal is quicker on a V8 than a 4 cylinder, I cant see how its not more feasable to remove

Remove Exhaust one side

Turbo housing + oli/coolant pipes

Exhaust manifold

Like I said, It would be good to know if anyone has done it as the 2 garages I have spoken with say its possible but others seem to think otherwise

Any more thoughts anyone ?

Cheers

Paul

[superdavelotus]

Hi Paul,

I've just been down to PNM in last half hour and spoke with mechanic there. He confirms what I've just said and that you can't even see the tops of the manifold nuts never mind trying to remove it.

As for this particular car needing a cambelt, it's easier for when owners having this problem of manifold studs snapping, many either get talked into other work being done on their car or waiting for such work to come up until they have their manifold studs replaced.

My friend Alan Corft had his studs done by them last year but couldn't wait any longer as they were blowing and noisy. He had to have his engine taken out. He didn't need any other work but whilst the engine is out, you might as well make a list, so he did. Any engine taken out should really change the cabelt for what it costs in parts. I've just had my cambelt change on my HC turbo whilst engine is out this week despite it only being change less than 1000 miles ago (albeit 2 years ago).

My friend Alan had his cambelt changed along with turbo water and oil pipes. I would recommend you do the same.

Oh, by the way, I am in no way knocking PNM by their service or abilities.

Regards,

David Walters

[Winter]

I am in the middle of an engine rebuild. It took my best pal and me 13 hours to take the engine out . . .

OK, one of us is 60 and the other is only a few weeks away from that milestone but even so, it's (literally) heavy and painstaking work - and we've removed several engines in our time. Sometimes they work when they go back in!

However, even with the engine out, I had to chisel several nuts off exhaust studs. It took two evenings (approx 3 hours per evening) to get the manifolds off, one per session.

Gird your loin particles.

[Guest modifiedv8engines]

Thanks for that Edward - some info on how long it takes to remove the engine is very useful and at least gives me some idea of the real time to do the job.

All I need now is to find out how long it takes to remove the manifold and if indeed this is possible.

Cheers

Paul

[mike_sekinger]

Hi Paul,

Did you manage the seemingly impossible?

Cheers,

Mike S

[Guest modifiedv8engines]

Hi Mike

No further forward as a recent holiday and the resulting flat battery meant I couldnt even move the car. Flat battery issue resolved and yesterday spent ( dodging rain clouds) removing water from the plug wells ( i should have used more sealant or someone should have designed the covers with a decent seal/gasket) meant no further forward with the exhaust manifold removal.

Had a word with my brother who is an ex-Lotus tech (1985 - 1995 approx. ) and he reckons the manifolds are removable with the engine in-situ at least from the 4 cylinder turbo as this was done at the old Lotus Service Garage . Would have thought the V8 to be simialr but just twice as much work if both sides need attention.

It is apparently a long and awkward job but still better than removing the engine which requires much grubbing about on your back, sitting/laying in the engine bay and requires a crane/gantry to lift the engine and trans clear of the rear transom.

Let you know how I get on when I get a chance to investigate further

Cheers

Paul

[Bibs]

Had a word with my brother who is an ex-Lotus tech (1985 - 1995 approx. ) and he reckons the manifolds are removable with the engine in-situ at least from the 4 cylinder turbo as this was done at the old Lotus Service Garage . Would have thought the V8 to be simialr but just twice as much work if both sides need attention.

That's an assumption too far Paul, the V8 is a much larger engine that the 4 pot and squeezed into the chassis much tighter. Saying that, it's not an easy job on the 4 pot but as mentioned it's nigh on impossible on a V8.

[Simon350S]

I'd not bother wasting my skin and blood on even atempting it.

Taking the engine and box out is not a difficult job and doesn't need a specialist lift with a rediculous reach as you can hoik it up over the side butresses. It'd be an ideal time to check EVERYTHING over and make sure the car is 100%

[Guest modifiedv8engines]

Hi Simon

Have you removed an engine from a V8 this way ?

Seems as though trying to remove the engine "sideways" would require more clearance than removing the engine from the rear. I put an engine and gearbox into a S3 Turbo some years ago and this wasnt so bad but the main concern if I decide to remove the engine from the Esprit is having sufficient height on the crane to clear everything.

Also had the engine out on my TVR which was a right arse of a job with next to no room to loosen/tighten the exhaust manifold so having been down the engine in and out route on more than one occassion I am prefering to remove just the manifolds on the Esprit if its possible.

To date forum members say no but PNM and SJ reckon its possible.

Anyone else out there care to contribute ?

Cheers

Paul

[percyporsche]

Why don't you try and remove the manifolds insitu and tell us if it can be done,at the end of the day you could have done it by now even if it is not possible.

[Guest modifiedv8engines]

Paul

If I had removed the manifolds I woudnt need to ask !

Either removing the manifolds in situ or removing the engine is a lot of work so it makes sense to see if anyone has removed the manifolds before starting.

Thanks for your comments

Cheers

Paul

[Guest modifiedv8engines]

Today was a dry sunny day so took the opportunity to get the Esprit up on ramps and investigate the possibility of exhaust manifold removal.

Fat chance since the lower nuts which hold or which partly hold the manifolds in place are obscured by the turbocharger, various other pipes, cables etc etc . So I took this opportunity to also investigate the other side and found a very slight coolant leak from the off side turbo. After chipping away some rust from where the stainless overbraid joins the steel 90 degree bend and union the resultant flow of coolant means I have another job to do....... .

So from what I could see, it looks near on impossible to remove the manifolds. Its looking like a an engine out job and like someone else said before,and trying to remain optimistic, this may be a good time to replace cambelt, all exhaust studs with stainless items, check the fuel tanks and sort out the oil weeping from the driveshaft seals.... and the oil and coolant pipes etc etc heat sheilds

Had the car 6 months and so far driven about the same in miles (6 )

Looks as though I may get this car back on the road after the summer .............or next year or ........

Paul