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[amba]

The removal of the heads was on the advise of a well respected forum member.

I had read that the nearside gasket could be done ,with difficulty and very limited access,without the head being removed,but the feeling was the potential risk of a stud snapping and then the need to remove head anyway outwayed the quick fix.

[Broomies Mate]

The removal of the heads was on the advise of a well respected forum member.

I had read that the nearside gasket could be done ,with difficulty and very limited access,without the head being removed,but the feeling was the potential risk of a stud snapping and then the need to remove head anyway outwayed the quick fix.

Whilst I dont want to step on anyones toes, why remove the head IF you dont have to.  You are just opening up potential for more problems.

The Head is aluminum, the studs are steel.  If they snap, a stud extractor can usually be used.  If not, remove the head for drilling.  I have done a huge amount of research on this subject, as mine needs doing (being done Thursday this week) and nobody, but nobody has suggested removing the heads to do the work unless absolutely necessary. 

[Marks DTM Calib]

The removal of the heads was on the advise of a well respected forum member.

I had read that the nearside gasket could be done ,with difficulty and very limited access,without the head being removed,but the feeling was the potential risk of a stud snapping and then the need to remove head anyway outwayed the quick fix.

Whilst I dont want to step on anyones toes, why remove the head IF you dont have to.  You are just opening up potential for more problems.

The Head is aluminum, the studs are steel.  If they snap, a stud extractor can usually be used.  If not, remove the head for drilling.  I have done a huge amount of research on this subject, as mine needs doing (being done Thursday this week) and nobody, but nobody has suggested removing the heads to do the work unless absolutely necessary. 

Agreed.

Not that hard to do nearside, just heavy on the arms and back as it all has to be done from below

[amba]

Suppose it was the preference of the mechanic then ?

Now I will have another think over my next step..gasket does need doing and when costing up the parts needed it works out at less than £40=00,compared to much/much more to remove the heads.

I had once thought about having a go at this myself but lots of potential nightmares seem to crop up..although do feel happier when read that the bolts snapping off seems to be the minority of cases.

Assume it is easier on axle stand than ramp ?

[geoffr70]

I was expecting some comments about changing the gasket when there was no need to! During disassembly, the hole in the rubber hose on secondary air injection should've been a giveaway - if only I knew what it was for at the time!

Thinking about it, the smoke on initial startup must be unrelated, but the noise appearing after 20 mins must be the amount of time it's taken for the hot gases to finally breach the rubber and make the hole. It has also melted the rubber under the quick connectors connecting to metal pipe, compromising integrity of connection, nevermind the hole!

Right, it has the standard exhaust, except a big twin 'D' shaped stainless steel tipped back box, embossed with Irmscher. I'm assuming this is factory fit, or aftermarket OEM, I didn't ask when I bought the car, but the box doesn't fit exactly 100% right in the cutout in rear bumper. With car running, but not hot, I can feel gases being forced out the secondary air injection pipe, from o/s bank back towards the front of car (this is wrong I take it), although I am able to cover the hole with my finger to stop gases without pressure being to great on my finger. 

Is the rubber pipe on secondary air injection a high heat hose, or I take it it must just be able to stand radiated heat from the engine bay? Motorfactors just gave me a scared kid look and didn't know what i was talking about! I've got flexible copper pipe from B and Q that I was going to use to bridge the gap, but from what MDTM says, it sounds like i must need to investigate possibility of exhaust blockage before going down this route. Which comes onto my next question! Is there an easier way, apart from disconnecting an exhaust section at a time to measure pressure to try and locate the blockage? I don't think so but I hope so!

Incidentally, brakes seem worse again with pipe with hole in - might be something to do with vacuum?!? I don't know.

On the plus side i took some photos when doing this so will attempt at making some sort of guide.

Line up if you want to call me a */'"-$!^ for changing exhaust manifold when I didn't need to! I think 20 nm for nuts is what it said in Haynes, although that goes to T mines a W, but can't be much difference?

[Kneepad]

I was expecting some comments about changing the gasket when there was no need to!

We are to polite for that. Anyway I think you've suffered enough.
 

[Abiton]

...Line up if you want to call me a */'"-$!^ for changing exhaust manifold when I didn't need to!...

I doubt there's many of us who've never misdiagnosed a fault and spent time and/or money fixing the wrong thing.   

Good luck with sorting out the residual problem.  Should be much easier than what you've done as a 'warm-up'. 

[geoffr70]

On the plus side I fitted a new HBV in the process, and got a whole load of lovely new coolant. I'm treating her to a oil change, and getting her a sister. A nice 3.0 litre MV6 manual saloon f/l, 2 owner, low miles, in Ferrero Roche colour. I'm spoiling her!

[Marks DTM Calib]

One option is to simply block the air injection off......its not really required.

Then, sooner or later, the side with the blockage will 'reveal' itself 

Do the cats rattle if tapped?

And what state are the two centre silencers in and what noise do they make when thumped?

[Marks DTM Calib]

I should add, its not high temp hose as it never gets exhaust gases through it under normal operating conditions

[geoffr70]

One option is to simply block the air injection off......its not really required.

Then, sooner or later, the side with the blockage will 'reveal' itself 

Do the cats rattle if tapped?

And what state are the two centre silencers in and what noise do they make when thumped?

Thanks Marks DTM Calibration! Sorry to be a pest! What is the best method for blocking 2ndary air injection off? Can this be done with pipe still on manifold? Do you have to do it on both banks, or can just one be done?

I'm intrigued how the blockage will reveal itself?!?!

I used to have a rattle on exhaust, I've got some big jubilee clips but haven't fitted them as rattle has gone, and i assumed it was heatshield on downpipe. It seemed to disappear when warm.

Centre silencers and Cats appear OK from observation when under car. i didn't take too much notice, only visual. O/S cat didn't rattle when pulling downpipe off manifold, don't know about n/s.

Thanks

[dad1uk]

Any chance of a photo that pinpoints where this pipe is, in case it is my problem......
I bet it isn't though

[geoffr70]

Hi dad1uk, I took some photo's during the job, and one in particular of the breached hose while still attached to the final SAI pipe before it goes to manifold, but off the car. I'll sort my camera out and have a look at uploading a few pics tomorrow.

[geoffr70]

The removal of the heads was on the advise of a well respected forum member.

I had read that the nearside gasket could be done ,with difficulty and very limited access,without the head being removed,but the feeling was the potential risk of a stud snapping and then the need to remove head anyway outwayed the quick fix.

Well I've never done this job but from my ever increasing amount of time spent under car doing various jobs, I would definitely attempt the n/s manifold gasket fom beneath, without removing head.

[amba]

Must say I am become more confident about having a go at the n/side gasket myself with what I read as the costs involved for the head removal/refit is considerable even at very competitive rates,especially when it seems possible to diy the job for less than half a tank of fuel.