Early exhaust left manifold pipe replacement!

[xpress]

Hi! The time has come to replace the early left hand exhaust mainfold u pipe! It's gone near where the clip is! Any ideas on how to approach taking out the two studs that go into the aluminium block! Would a stud extractor do the job! Or weld a nut to the nuts there and impact drill them out! Any tips from wisemen! Also when replacing should I use plenty of exhaust paste for the joint and a new clip! How much paste should I use!

[itchyfeet]

Are they all studs or some bolts? If studs can you get the nuts off? If bolts will they turn?

Which bit do you mean?

if the j tube is shot and you have studs you could cut through the tube and pull the parts off the studs, then remove the tube left from the join
replacing with new the same way by sliding back over the studs and sliding the two parts together.

thats all assuming they dont snap

dont need paste just a new gasket and preferably copper nuts or stainless will do

[ianboydsnr]

Why would you want to remove the studs, are they corroded?

You need a stud extractor, much heat!

[xpress]

That doesn't look like my early lh manifold pipe! Can anyone chime in with advice on the early pipe!?

Where's the best place for stainless nuts and what size do I need! Going yo get an irwin to remove these nuts off the head studs! Where to go for the gaskets!

[itchyfeet]

That doesn't look like my early lh manifold pipe! Can anyone chime in with advice on the early pipe!?

Where's the best place for stainless nuts and what size do I need! Going yo get an irwin to remove these nuts off the head studs! Where to go for the gaskets!

Ok i assumed you had a wbx, perhaps its Aircooled?, if you put your van details in your sig it would save wasting time guessing.

[xpress]

Sorry it's a 1.9 dg but early exhaust!

[itchyfeet]

Sorry it's a 1.9 dg but early exhaust!

Ok so whats shown is an early exhaust for a dg, if yours looks different you probably have a non std exhaust, get a pic up of what you have.

[CovKid]

The only other slight difference might be the addition of a pre-heat exchanger on the right, but Itchyfeet is right - thats the early exhaust - similar to that fitted to some bays too.

[xpress]

I just have the replacement u pipe from gsf! So it may sleeve into that opposite end piece as pictured!

Can anyone tell me what size replacement stainless nuts I will need for the engine head side and is it studs and nuts the other end? Or a clip around the sleeve? What sort of fixings will I need! The haynes isn't clear! And two gaskets! Please help me make up a shopping list!

[itchyfeet]

Nuts are m8, if bolts get m8x25 get flat washers too
gasket
http://www.brickwerks.co.uk/index.php/t ... udget.html" onclick="window.open(this.href);return false;
im sure gsf will have them too

something lik this will do for the clamp, you want 40mm but check the diameter with your pipe to see if its just over or under 40mm
http://www.ebay.co.uk/itm/Genuine-MIkal ... 2ed1f6a83e" onclick="window.open(this.href);return false;

[xpress]

Thanks for that! I will keep you posted!

[xpress]

I took another look at the clamp, there's a large clamp piece like the picture without a bolt and nut, and behind it towards the bumper is a hose clip! Maybe the big clamp helps to secure it as one piece and cuts down on flex, which could cause the j tube to fracture where it connects into the muffler pipe! Exactly as it did with my situation! Did you reuse the large clamp piece!?