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Excel Manifold Replacement - tips & tricks


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Hi all, I knew I had a couple of holes in my exhaust, but now discovered that very probably have a leak in the exhaust manifold also :-(. Will know for sure once on a ramp when we can check properly. Not that experienced myself, but will tackle with my brother who has plenty - albeit not with Lotus's. 

Can anyone point me to any help / tips and tricks? Is it and engine out job, or can it be done in situ?

Ps..I have a 1988 Excel

Edited by StevoExl
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The manifold is notoriously difficult to remove - corrosion of and restricted access to the studs being the issues.  If you can get the down pipes off and then undo the n/s engine mount and raise the n/s of the engine that will help.  Dig out your dictionary of expletives!!  😉  The later (like yours) manifolds crack much less often than the earlier ones though.  However - once you get it off you may find you need to perform a bit of surgery on the three studs at the bottom of the manifold - they sometimes shear off and need drilling out/replacing.  Let us know how you get on.

Pete

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Thank you very much Pete....will take your advice on the expletives 😂. My fingers are crossed that it's ok, but my brother had his stethoscope out and is convinced he can hear it blowing. 

Cheers

Steve

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  • 4 months later...

Talking of those 3 studs at the bottom, how on earth did they ever tighten them originally? if I'm lucky I can turn the single nut at the back a quarter of a turn at a time. Did they have a special tool or adapted tool or tighten it before the body went on?

I can't be the only person to have difficulty with this but I expect it's a case of undoing each nut a little bit at a time, but I can't help thinking someone must have come up with some sort of tool albeit a bent spanner or similar.

I welcome any constructive hacks or hints

 

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Think yourself lucky, the early Esprit Turbo manifolds were far worse for access.

 

This isn't going to help with removal but Ford studs (which have a Torx end) and associated copper nuts are a much better solution for putting it back together.

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2 hours ago, andydclements said:

Think yourself lucky, the early Esprit Turbo manifolds were far worse for access.

 

This isn't going to help with removal but Ford studs (which have a Torx end) and associated copper nuts are a much better solution for putting it back together.

Andy, have you a link for the Ford bits? @andydclements

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