eec564 Posted November 18, 2006 Share Posted November 18, 2006 So, my exaust manifold has developed a rather large leak, and I sound like a motorcycle with straight pipes. I've removed everything I can imagine that could be holding the intake manifold on, including the fuel rail, EGR, coolant hoses, air intake, vacume hoses, the four intake manifold bolts, etc. I should just be able to wiggle the manifold and pick it up off the head, to get to the exaust underneath, right? I was under the impression the the heat shields that you cannot get to without taking off the intake manifold were attatched to the intake manifold, and wouldn't impede my removal. Any help by anyone who's done this on an engine that's still in the car would be great. In case for some reason my signature decides not to show my car specs, it's an 82 280ZX non-turbo, totally stock. Quote Link to comment Share on other sites More sharing options...
SLVRBLLT40 Posted November 18, 2006 Share Posted November 18, 2006 When I took the intake manifold off my 240Z, there were alot more than 4 bolts holding it on. The exhaust manifold and intake manifold share several bolts and they are all on the underside of the intake. I had to take my heatshield off to even get to them. So try taking a look at that, if you haven't already. Quote Link to comment Share on other sites More sharing options...
mrparks Posted November 18, 2006 Share Posted November 18, 2006 The heat shield that runs 90 degrees from the intake is bolted on, I think they're 12mm. You have to get those off first. Feel around with a 12" extension for the other 12mm intake and exhaust bolts. I don't recall the exact number of bolts. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 18, 2006 Author Share Posted November 18, 2006 Okay, I'll get all the heatshields off and get under there with a mirror and flashlight. It wasn't clear at all from the downloadable FSM from carfiche that there were any intake bolts under the intake. Thanks so much, I'll get on it AM tomorrow. Quote Link to comment Share on other sites More sharing options...
johnc Posted November 18, 2006 Share Posted November 18, 2006 There are bolts under the intake that hold the exhaust manifold and intake manifold on via thick washers that push on tabs on each manifold. Unfortunately, you'll most likely have to pull the exhuast manifold too because the combined intake/exhaust gasket will probably get damaged. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 18, 2006 Author Share Posted November 18, 2006 Yea, I figuered I'd have to pull everything and I already picked up one of those absolutely huge gaskets. One thing I was presuming (just like every other car I've worked on) is I'd be taking off the intake first, since it's on top. But I notised there's that little plate in the webbing between cyl 3 &4 that lets you get to one of the exaust manifold bolts. I don't need to take off the exaust first, do I? I wouldn't think (hope) so. Once I get the heat shields off I should be able to get to the rest of the bolts for the intake. I also think I broke an exaust stud, (which caused the leak in the first place) such as the one around cyl 6, so I also have plans to use my EZ-outs and some new studs/nuts. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 18, 2006 Author Share Posted November 18, 2006 Okay, I got the intake and exaust manifolds off, thanks so much for the tips. Lo and behold, the exaust broke in half right below the 2-into-1 collector. That would explain why I was louder than any sane car on the road. Looks like it's off to a welding shop for me, as it looks like it may have been welded before and will need to have about two inches cut out and fit with new pipe. Quote Link to comment Share on other sites More sharing options...
savageskaterkid Posted November 19, 2006 Share Posted November 19, 2006 If this is a stock manifold, and it was welded once already, I'd trash it now. Cast iron is hard to weld, specially if new metal has to be introduced. Headers arn't that expensive, even from MSA. You can easily find manifolds in the junkyard. If not I'm sure someone on here will give you theres for the price of shipping. If I still had mine I'd give it up, but it broke while I was taking it off. Quote Link to comment Share on other sites More sharing options...
Hartspank Posted November 19, 2006 Share Posted November 19, 2006 I just picked up a MSA header and it also comes with the 2-1 pipe.It was around $200 w shipping. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 19, 2006 Author Share Posted November 19, 2006 It's not the manifold/header that's broken, it's the section after the 2-1 that's part of the exaust that runs down to the cat. Just above the 2-1 before the break is where the manifold bolts to the rest of the system. I was gonna cut out the entire section that's either been welded or just looks that way due to rust and weld in a new section of pipe. I just can't decide now if I should buy a cheap wirefeed welder or take it somewhere. Also, being in CA any parts I add would need to have a CARB number to be leagal for use on a smog controlled vehicle. Anyone local to Oakland wanna drop in with a welder? Quote Link to comment Share on other sites More sharing options...
savageskaterkid Posted November 20, 2006 Share Posted November 20, 2006 oooo. your talking about the head pipe, or atleast thats what I always called it. Quote Link to comment Share on other sites More sharing options...
Noddle Posted November 20, 2006 Share Posted November 20, 2006 It's not the manifold/header that's broken, it's the section after the 2-1 that's part of the exaust that runs down to the cat. Just above the 2-1 before the break is where the manifold bolts to the rest of the system. I was gonna cut out the entire section that's either been welded or just looks that way due to rust and weld in a new section of pipe. I just can't decide now if I should buy a cheap wirefeed welder or take it somewhere. Also, being in CA any parts I add would need to have a CARB number to be leagal for use on a smog controlled vehicle. Anyone local to Oakland wanna drop in with a welder? Got a camera ?, a picture is worth a thousand words.. then every one will know exactly what you are talking about. Quote Link to comment Share on other sites More sharing options...
VG33TT Posted November 20, 2006 Share Posted November 20, 2006 You will want to have the manifold resurfaced also. Its probably warped. Quote Link to comment Share on other sites More sharing options...
JessZ Posted November 20, 2006 Share Posted November 20, 2006 I recentley finished school there. I'm in S.F. now, if I can help let me know. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 20, 2006 Author Share Posted November 20, 2006 Here are some pictues: The pipe going to the cat Another angle The Manifold Another view Yet another Still more JessZ, thanks for the offer, but I'm hoping I can handle it. I got my hands on a nice cheap buzz-box and I'm gonna see what I can do, but I may just line everything up, tack it together, and take it down to a muffler shop. That is, providing I can unbolt the pipe from the front of the cat. Quote Link to comment Share on other sites More sharing options...
randy 77zt Posted November 20, 2006 Share Posted November 20, 2006 when you start welding old rusty metal it blows away-you could probably find a better head pipe at pick&pull.pulling the exhaust manifold was a hard way to get a 30 minute job done.get the exhaust manifold surfaced at a machine shop-it warps after you unbolt it. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 20, 2006 Author Share Posted November 20, 2006 I ended up pulling it because I absolutely couldn't find the leak. It didn't fall into two pieces until I unbolted everything. I'm not so worried about welding on it, I'm just gonna cut out the rusty part. Asside from maybe 1" of rust along the pipe, everything else is rock solid, I've been checking it with a pointy hammer all over. Also, after getting everything out I found my gasket broken in several places also. Quote Link to comment Share on other sites More sharing options...
eec564 Posted November 22, 2006 Author Share Posted November 22, 2006 Okay, I welded it. It's now very, very quiet. I'll post pics later, but it turned out interesting and extremely restricted. Later, I'm just going to make a new flange/2-into-1 piece from a piece of sheet iron and some tubing. Quote Link to comment Share on other sites More sharing options...
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