Exhaust manifold gasket blown

Dr. Rog · Sep 21st, 2010, 20:37

Unbelievable.

I have only had this car long enough to put petrol in it once (and haven't even go the needle of the full.)

I am on my third fault!

The exhaust manifold gasket has blown at the front, what is worse it is because the bottom front stud has been replaced by a bolt, and a small one at that (10mm across flats -M6?)

I gave it a tweak but it has clearly damaged the thread a it turns easier than when I started.

I am incensed. This is clearly a bodged repair, and I didn't see it when I bought it, that really hurts.

Any advice?
Is this a turbo-off job?
How log should a competent mechanic take, bearing in mind he is clearly going to have to drill and Helicoil the head?

I intend giving it to a recommended mechanic as it needs a new timing belt and some bits from the old car fitted, as well as the usual service items. I don't have the time for so much work so a bit of this chaps time will be OK.

TonyS9 · Sep 22nd, 2010, 02:15

Yes definitely annoying when someone ruins softmetal like that. Try a proper metric stud or bolt first, it maybe too short or some imperial job. The stud should be 8mm I think (mine measures 7.5 on the exposed part, but rusted).

If it needed lined then I would imagine the turbo and manifold have to come off, I'd guess 3-4 hrs for the majority of the work diss-reassembly, not sure how long the lining takes.

Interestingly my very same nut was also loose, as was a few of the other nuts, but it doesn't leak (noticeably).

Easy Rhino · Sep 22nd, 2010, 06:14

The exhaust manifold to head gaskets failed on my old BF230 Volvo 940, and the job was not that bad except that the manifold bolts can be finicky, as I stripped one out requiring a helicoil repair.

1stRaven · Sep 22nd, 2010, 13:57

It will be a turbo off job if everything's stock.

Dr. Rog · Sep 22nd, 2010, 17:54

Cheers guys,
Apparently the parts are cheap, its just the labour is the issue.
I have booked it in next week with the recommended mechanic. He recommended getting the turbo oil return seals/gaskets which I hope I have ordered from Braydons.

The chap who recommended him (a mutual mate) has helicoils.

Sep 21st, 2010, 20:37	#1
Dr. Rog Master Member Last Online: Oct 21st, 2017 22:15 Join Date: Aug 2010 Location: Kingsclere	Exhaust manifold gasket blown Unbelievable. I have only had this car long enough to put petrol in it once (and haven't even go the needle of the full.) I am on my third fault! The exhaust manifold gasket has blown at the front, what is worse it is because the bottom front stud has been replaced by a bolt, and a small one at that (10mm across flats -M6?) I gave it a tweak but it has clearly damaged the thread a it turns easier than when I started. I am incensed. This is clearly a bodged repair, and I didn't see it when I bought it, that really hurts. Any advice? Is this a turbo-off job? How log should a competent mechanic take, bearing in mind he is clearly going to have to drill and Helicoil the head? I intend giving it to a recommended mechanic as it needs a new timing belt and some bits from the old car fitted, as well as the usual service items. I don't have the time for so much work so a bit of this chaps time will be OK. __________________ Cheers Rog Previously owned 1996 940 SE auto and GLE manual, both B230FK estates.

Sep 22nd, 2010, 13:57	#4
1stRaven Forum Support Team Last Online: Mar 14th, 2018 13:07 Join Date: Mar 2006 Location: Lincoln View Photos By: 1stRaven	It will be a turbo off job if everything's stock. __________________ *700R Website*

Sep 22nd, 2010, 17:54	#5
Dr. Rog Master Member Last Online: Oct 21st, 2017 22:15 Join Date: Aug 2010 Location: Kingsclere	Cheers guys, Apparently the parts are cheap, its just the labour is the issue. I have booked it in next week with the recommended mechanic. He recommended getting the turbo oil return seals/gaskets which I hope I have ordered from Braydons. The chap who recommended him (a mutual mate) has helicoils. __________________ Cheers Rog Previously owned 1996 940 SE auto and GLE manual, both B230FK estates.

Sep 22nd, 2010, 02:15	#2
TonyS9 Premier Member Last Online: May 19th, 2024 20:22 Join Date: Jul 2009 Location: Holywood	Yes definitely annoying when someone ruins softmetal like that. Try a proper metric stud or bolt first, it maybe too short or some imperial job. The stud should be 8mm I think (mine measures 7.5 on the exposed part, but rusted). If it needed lined then I would imagine the turbo and manifold have to come off, I'd guess 3-4 hrs for the majority of the work diss-reassembly, not sure how long the lining takes. Interestingly my very same nut was also loose, as was a few of the other nuts, but it doesn't leak (noticeably).

Sep 22nd, 2010, 06:14	#3
Easy Rhino Senior Member Last Online: Nov 1st, 2015 20:39 Join Date: Nov 2007 Location: Kailua, HI	The exhaust manifold to head gaskets failed on my old BF230 Volvo 940, and the job was not that bad except that the manifold bolts can be finicky, as I stripped one out requiring a helicoil repair.

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