How to remove exhaust manifold S40/V40

tritone88 · Post by **tritone88** » 24 Jul 2012, 10:00

Hi,

I have a 2000 S40 1.9T. There are several links to the VADIS instructions on how to remove the cylinder head for an S40/V40. One of the first steps is to remove the exhaust manifold. There is a link entitled and underlined "Replacing Exhaust System". I wonder if anyone out there can send me the VADIS pdf for this step.

I have everything removed with the exception of the exhaust manifold and am ready to pull the head. I'm just wondering if there is an easy way to move the exhaust manifold back and out of the way towards the firewall without dismantling the entire exhaust and turbo?

Thanks

BuellS40 · Post by **BuellS40** » 27 Jul 2012, 22:49

there are 8 nuts holding the manifold to the block. Unbolt them, remove the studs (carefully, you do not want to snap one), and the manifold will be free of the engine.

tritone88 · Post by **tritone88** » 30 Jul 2012, 09:33

Thanks for your reply. It turned out not to be as easy as that. First thing I did was remove the 8 exhaust manifold nuts as you suggested but I couldn't pry the manifold back towards the firewall without removing a variety of pipe connectors that kept the manifold from dislodging. I had to remove the oil line to the turbo, the water line to the turbo, some bracket underneath keeping 2 pipes from moving and the 4 bolts on the exhaust down pipe. After all that, there was enough play to pry the manifold off the studs.

BuellS40 · Post by **BuellS40** » 30 Jul 2012, 12:26

It might have been a little easier if you could have removed the studs, as well as the nuts. I know there isn't much room to work back there, as i just replaced my manifold gaskets. Another thing that could have been done, although the info might not be very useful now, is loosening the nuts that attach the turbo to the down pipe, it might have given you a little more play in the manifold, at least enough to clear the head.

tritone88 · Post by **tritone88** » 30 Jul 2012, 12:50

Yup no room back there. Four of the studs came out but the others stayed in. Yeah loosening the turbo nuts might have worked too. It was n't as bad as I thought just loosening the turbo oil and water pipes. The headset comes with new brass washers so I guess they think someone is going to disconnect those.

Since it sounds like you've done the entire job, removing the cylinder head, did you have any trouble with the 40 Torx or is it 45 that holds the exhaust cam CVVT gear? I have the cam locked and I have a breaker bar with six foot extension on it and the thing won't budge. I need to remove it so I can put in the new cam seals.

Post by **zulu-v40** » 02 Aug 2012, 10:49

So, the manifold can be removed even if a stud is stuck? How did that work? I've got a stud that's sheared off and need to do the same procedure. Can you share a bit about how the manifold came off?

tritone88 · Post by **tritone88** » 02 Aug 2012, 11:01

If I understand your question, you still have one or more studs still in the head but all of the stud nuts have been removed and one broke off? What I did was start under the car by removing the four nuts holding the downpipe to the flex exhaust. Then I undid both the turbu oil connector and water connector banjo bolts. Then I went back under car and noticed two pipes held together with a bracket fastened with a 10 mm nut. The bracket just keeps the pipes anchored to one another. If I recall that was enough to get a large screww driver behing the manifold and pry it off the studs.