Thread: TD5 Exhaust manifold mods

You will have to have the head shaved to ensure it is true.

Get larger studs - M8 to M10. Then as we say "she'll be right, mate"

to add -

New gasket
Drill holes in manifold to suit M10 studs.
New nuts with washer and spring washer

Originally Posted by catch-22

You will have to have the head shaved to ensure it is true.

Get larger studs - M8 to M10. Then as we say "she'll be right, mate"

to add -

New gasket
Drill holes in manifold to suit M10 studs.
New nuts with washer and spring washer

Dont know about shaving the head, first up before a desision is made run a straight edge along it and then check it against the specs.
cheers
blaze

Originally Posted by Rudolf

The constant whistle during boost made me look further.
Looking at manifold form turbo side.
The most righ top stud was broken off inside the head.
While trying to remove the "Easy Out" broke and is also now stuck.
Then decided to remove manifold rather to make access easy.
This brought another carcked now broken stud out. Most left top.

Can one grind the web stiffeners away on a used manifold and do I enlarge the most outer holes (Left & right) to prevent expansion braking the studs?
The manifold does not seem warped as the leak was to be minimal.

Any advice please.

Appologies to bother you lot on a Sunday evening.

Here is how someone else has done it.

Originally Posted by slug_burner

Here is how someone else has done it.

Thanks
Going to give it to some one else to do.
Just assembled it again and used "Firegum" exhaust sealant to get it going again.
The leak on mine is not as bad as on that web site.

Same two studs went on mine after putting the head back on
Front one cleaned up with a blind tap.
Back one ended up being helicoiled, larger thread in head with no mods to manifold this way.

Cheers.

Hi Rudolf.
Its the manifold NOT the head that may need machining.
Once you cut the webs out of the manifold you may find its flat enough.
Ive done mine,once I removed the webbing it was mutch flatter.I drilled the outside 4 holes up a size or 2,also fitted a second nut to the studs (as a locknut)as I found 2 nuts sitting on the manifold.
No problems since the mods.
Goodluck
Andrew

Everything is back on but then...
I noticed that I broke the Oil pressure switch earth wire and cannot see where it goes.
Rerouting it from the front left earth.
Will have the stuck stud repaired shortly and also replace all the studs with new ones.

Originally Posted by bblaze

Dont know about shaving the head, first up before a desision is made run a straight edge along it and then check it against the specs.
cheers
blaze

Cheers mate...yeah meant shave the manifold. Thanks for the correction.....