Technical cracked manifold

[Trickey Dickey]

just a quick question, i think i have a cracked exhaust manifold, its blows when its cold but seems to stop when its warm, whats my best option? do i buy a new manifold?? or can i get it welded? has anyone done this and what sort of cost are involved??? is it diy friendly to remove and replace?? im quite good with a spanner or two!!! any info gratefull guys and girls

 

[bulldog5046]

it depends on where the crack is to how bad it can be but yes they can be welded.

removing it is not the simpilist things, ideally check out the how-to guides on FCCUK.org/forum

there is a fella there who will weld yours if you like or will send you a welded one for £150 and give £30 back if you return your old one if i remember rightly, his name is countrycruising

i wouldnt leave it as fragments can come lose to ruin the turbo

Thanks,
Ry

 

[hmallett]

Removing the manifold is particularly awkward if you have aircon. You can weld them, but it'll probably crack again at some point. You can buy a new manifold for not too much money... though it may crack too.
New manifolds have more strengthening on them to prevent cracking in the weak spots. Instead they just crack somewhere else!

 

[bulldog5046]

Removing the manifold is particularly awkward if you have aircon. You can weld them, but it'll probably crack again at some point. You can buy a new manifold for not too much money... though it may crack too.
New manifolds have more strengthening on them to prevent cracking in the weak spots. Instead they just crack somewhere else!

new manifold is close to £350 part only, i thought that seemed expensive!

 

[Trickey Dickey]

do you think it could be as simple as the manifold gaskets may be fxxkxd? or more than likely its cracked??
does anyone have a link to removing the exhaust manifold?? when ever i try to get on fccuk it never seems to work for me any help would be good guys and gals

 

[Mark20v]

They are not the worst things to remove and replace unless bolts sheer etc...

Remove heat shield, fans, oxygen sensor - they are the easy bits.

Loosen exhaust support under the car and then the turbo (this can be a pain as not all the nuts are easily accessible), lower the turbo/exhaust a little then you will have easy access to the manifold. Undo the nuts and remove it.

Make sure you get a new exhaust manifold gasket at the same time - there are a number of modified and welded manifolds doing the rounds, mostly done by a guy called Carlt as already mentioned - they are very good. A new manifold will cost you a few £ to buy - try and source one of Carls (fccuk is your best bet).

As someone says above, if you have aircon theres a bit more to do.

It seems daunting but isnt the worst job - getting to the rear turbo nuts is the worst bit.

To check if its cracked and it almost 99% is, simply remove the heat shield (3 bolts I think) and you will see the manifold - the far right branch as you look at it will probably be cracked and maybe also a crack to the left of the manifold as you look at it where the branches meet just above the turbo.

 

[symonh2000]

Mine has a cracked manifold as well. I have decided to leave it until either it gets worse, or until the radiator needs changing.

Later ones had part of the mounting plate removed between cylinders 4 and 5, as this part expanding was causing the branch to crack near the turbo flange.

 

[Mark20v]

Countrycruising on fccuk is doing a batch at the moment - I dont personally have experience of his manifolds but he gets great feedback from people so worth a look.

 

[symonh2000]

I hear he used to be a welder for British Nuclear fuels LTD so he should know his stuff. He doesn't just weld the crack the whole manifold is destressed after by heat soaking in a furnace. I am not sure if modifies the mounting plate like on the later manifold though.

 

[bulldog5046]

I hear he used to be a welder for British Nuclear fuels LTD so he should know his stuff. He doesn't just weld the crack the whole manifold is destressed after by heat soaking in a furnace. I am not sure if modifies the mounting plate like on the later manifold though.

i dunno about working for BNF but he is a blacksmith, i met him recently and he dropped me a manifold he had repaired, it seems good but i havent tested it.

and yes he told me he does heat them up in the furnace after TIG welding them to check they wont crack again

 

[symonh2000]

i dunno about working for BNF but he is a blacksmith, i met him recently and he dropped me a manifold he had repaired, it seems good but i havent tested it.

and yes he told me he does heat them up in the furnace after TIG welding them to check they wont crack again

I stand corrected then. Does he cut the mounting plate between the 4th and 5th branch? As that was the mod done by Fiat on the later manifolds to prevent the cracks in the first place.