Topic: Exhaust Manifold trouble (Read 5818 times)

Brynjaminjones · « **on:** January 26, 2014, 08:44:26 PM »

I'm not a happy chappy today.

I've spent the best part of two days fitting my new exhaust manifold, only to find that I'd not seated the intake properly and so was greeted with an engine that sounded like it was ready to rev up to about 3,000,000rpm the moment I started it.

What myself and my mechanic realised upon closer inspection was that the flanges on the exhaust manifold (where the bolts hold them) are thicker than those on the intake manifold, meaning that surely it's impossible for the intake manifold to be held on properly??

I'll attach a couple of pictures - although not very clear they should still show you what I mean.

Is this normal, or do I need to get a new manifold??

Dave The Sparky · « **Reply #1 on:** January 26, 2014, 09:52:27 PM »

Incorrect part? so will they take returns or is it from the US? in which case i suggest you need to find a friendly engineer who will mill the manifold down to the right thickness for you

scrw · « **Reply #2 on:** January 26, 2014, 09:58:36 PM »

grinder time! just take some meat of the ears that have the shared bolt on them

WTF were you doing, 2 days!

Brynjaminjones · « **Reply #3 on:** January 26, 2014, 10:01:19 PM »

'Tis from the US unfortunately. It looks to be the right part - it has the right number and fits perfectly in every other respect. Rockauto used to sell them but has now stopped; I'm wondering if this is why?

Anyway, I think I'm going to just buy a different one, as I don't know where I could get it milled, and if I leave it be I may be able to pursue as it came from Amazon.
P.S. I'm fairly new to this whole "using a spanner" thing, so took my time, faffed about a bit, got stuck on some parts, and generally made it take longer than it should have done!

Bulldog67 · « **Reply #4 on:** January 26, 2014, 10:06:35 PM »

bigjeepzj · « **Reply #5 on:** January 26, 2014, 10:08:51 PM »

your uni got a engineering department ??

Brynjaminjones · « **Reply #6 on:** January 26, 2014, 10:10:19 PM »

Quote from: bigjeepzj on January 26, 2014, 10:08:51 PM

your uni got a engineering department ??

It does indeed, and I'm even let loose in there sometimes! I need the XJ back ASAP though, and I don't think I'd be able to get anything done in there quickly. Maybe once I've got a new one on I could fix the other one and keep it or sell it on!

bigjeepzj · « **Reply #7 on:** January 26, 2014, 10:19:37 PM »

put the old one back on for the mo ?

Brynjaminjones · « **Reply #8 on:** January 26, 2014, 10:23:38 PM »

Honestly, I'm lazy, and I just want this done and out of the way!

I've just ordered a manifold on eBay the same as Maf (Green Jeep) recommended to me ages ago (and I should have gone for all along!), so hopefully I should be able to get that fitted next weekend!

bigjeepzj · « **Reply #9 on:** January 26, 2014, 10:35:26 PM »

ok mate

Brynjaminjones · « **Reply #10 on:** January 26, 2014, 10:42:30 PM »

I appreciate the help though

JamesH · « **Reply #11 on:** January 27, 2014, 09:02:42 AM »

My Pacesetter headers came with stepped washer things for that problem cos the same problem occurred but it was the other way round with the intake being thicker.

Brynjaminjones · « **Reply #12 on:** January 27, 2014, 09:43:34 AM »

Really?? Might it be possible to get a photo of one, or are they all too hidden?

EDIT: Nevermind the photo, I've found what some look like now. They seem like the perfect solution, but I haven't a clue where to find them!
In case anyone's unsure what I'm looking for, scroll down to the last post on this page: http://blog.hemmings.com/index.php/2007/04/page/4/

bgbazz · « **Reply #13 on:** January 27, 2014, 10:30:00 AM »

If you're handy with a grinder, you could make these yourself.

bigjeepzj · « **Reply #14 on:** January 27, 2014, 10:57:17 AM »

and these
http://www.ebay.co.uk/itm/Stainless-M8-Extra-Thick-Spacer-Washers-Choose-Your-Quantity-/370956028554?pt=UK_DIY_Material_Nails_Fixing_MJ&var=&hash=item565eb3ca8a

Brynjaminjones · « **Reply #15 on:** January 27, 2014, 01:35:43 PM »

I've never actually used a grinder before, so wouldn't really know what I was doing!

One more concern I have - is it likely that I may have cracked my intake manifold by putting it on wonky and tightening it up??

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JamesH · « **Reply #16 on:** January 27, 2014, 01:48:33 PM »

I think it'll be fine. Mine did the same thing when I fitted the headers and got a couple of the special washers the wrong way round (they spin around a bit when fiddling under the intake to fit them)

Brynjaminjones · « **Reply #17 on:** January 27, 2014, 02:49:52 PM »

That's good to hear!
It makes me feel much better to hear that you've done similar - it was really making me doubt whether I should be doing stuff like this myself instead of taking it to a garage!

bigjeepzj · « **Reply #18 on:** January 27, 2014, 03:49:47 PM »

keep at the spannering made.
having a go is the best way to learn

Dave69 · « **Reply #19 on:** January 27, 2014, 06:15:53 PM »

you have to learn to think outside the box,

get washers cut to suit the gap then bolt into place using spring washers with the split side over the spacers. if you broke the original manifold what would you have done?

bgbazz · « **Reply #20 on:** January 27, 2014, 06:59:23 PM »

..improvise!

bluevanman · « **Reply #21 on:** January 27, 2014, 09:24:26 PM »

stepped washers deffo the way to go. used to use them all the time on old minis with odd manifolds way back in the day

Brynjaminjones · « **Reply #22 on:** January 27, 2014, 10:01:28 PM »

If I can find some then I'll use them - due to time I can't really make them myself. Do you have any idea where to get them from??

Dave69 · « **Reply #23 on:** January 27, 2014, 10:13:55 PM »

stepped washers would normally be bespoke to the application, its a case of finding something and making/adapting them

Dave69 · « **Reply #24 on:** January 27, 2014, 10:15:58 PM »

if you want to modify your manifold give me a shout and i'll try and fit some time in

Author Topic: Exhaust Manifold trouble (Read 5818 times)

bluevanman