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Thread: How to Remove the Exhaust Manifold?? (late BJ8)

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    How to Remove the Exhaust Manifold?? (late BJ8)

    Hi All - I'm a new owner of a late BJ8, and new to the forum. Can someone please post the order of operations for removal of the exhaust manifold. Gaining access to the fasteners, especially the ones on the bottom, has me baffled. I'd appreciate your help.

    Thanks Again,
    Crispy, 67 BJ8, Portland, OR

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    As a new owner, you will need a factory shop manual. It will give you step-by-step information on just about everything.
    Get one - you won't be sorry.
    Bob

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    I have a BJ8, and I haven't removed the exhaust manifold in situ, but I think it's doable (I assume the engine's still in the car?). You'll need to get the car on a lift or at least jackstands; most of the work will be from underneath (be safe). You have to undo the nuts on the studs on the bottom flange to disconnect the down pipes; if your pipes' flexible sections are in good order you shouldn't have to pull the pipes out of the muffler. The nuts are likely brass and should come off fairly easily, but if you have to really torque on them you could snap a stud, which means you're committed to removing the manifold*; I use a ratchet with a couple long extensions and a deep socket. The top nuts on the studs on the head should be accessible, but I don't know about the bottom ones (you should be able to tell when you get under the car). Some of the nuts clamp both the exhaust and intake manifolds; I don't know if it's absolutely necessary to remove the intake manifold, but it would certainly make things easier. The hard part of getting the intake manifold off is getting the carburettors off, esp. the rear as the bottom nuts on studs are hard to get to; some of us have modified wrenches--1/2"--to make the chore a little easier (I use a 'stubby' wrench I got from Harbor Freight).

    I don't have my shop manual handy, but I don't recall any instructions for R&Ring the manifolds; it's pretty self-evident what needs to be done.

    EDIT: When reinstalling, check the manifold->downpipes and downpipes flanges. The manifold flanges can erode or even warp a little, sometimes making it difficult to get a good seal, and repop downpipes' flanges are sometimes installed erratically (flat-filing may be in order). The repop gaskets are failure-prone--since they can't use asbestos anymore--and I haven't had good luck with the brass nuts; double-nutting with steel nuts and a good anti-seize works for me. Use a high-temp sealant on the gasket for good measure.

    * I broke one once with the engine in the car, but was able to get the stud out by MIG-welding a nut onto the remnants of the stud.

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    From below use a 1/2"deep well swivel socket on an 18" extension to remove flange nuts. The heat shield will make it almost impossible to remove them without removing the intake. I did drill holes in mine to allow me to loosen and tighten the nut if ever necessary. The Carbs have to come off using a 1/2" stubby open end to remove the heat shield. Use 9/16 socket on the lower exhaust manifolds, you can reach under and feel them to install the socket with a 6" extension. The upper ones are easier to see and remove. I have bought extra open end wrenches at garage sales in the past and used a sawzall to cut them down to 1-2" long-much shorter than stubby wrenches available commercially.

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    screenshot.1680.jpg

    Or direct from Bentley:
    screenshot.1681.jpg
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
    http://www.pbase.com/stevegerow


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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Suggest shooting the exhaust stud nuts with Kroil or PBblaster before undoing, though they are often super-clean from the heat.
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Thanks guys, very helpful :-). I do have the manual published by Bentley, pictured above. I have a half height lift so hopefully that will make things a bit easier.

    So I'm assuming the carbs and the intake manifold have to come off 1st? Can anyone confirm that is true?

    If so, then how to i get a wrench on the lower right nut on the rear carb? I don't see an obvious way in. Do I get there from the top, or the bottom?

    Really appreciate you help...thankyou.

    Crispy, 67 BJ8, Portland, OR

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    ...and yes, the engine is in the car...and its gonna stay there!! ;-)

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    The carbs come off first. That bottom rear nut needs to be reached with a short open end wrench from the top. It's easier if you have the throttle linkage out of the way.

    The manifold nuts can also be reached from the top with an open end wrench. You will be working blind, though.
    John, BN4

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Crispy

    Having a 100 I can't give you specific advice on your BJ8 but I can suggest that you get a set of 1/4" drive sockets with a few extensions and a universal and also some stubby wrenches. Though it may seem impossible to reach and undo some fasteners this is simply a part of the diabolical scheme to test your mettle. Stick with it and keep us posted.

    Best--Michael Oritt
    1954 Austin-Healey 100 Le Mans
    1958 Elva Courier (FOR SALE)
    1959 Elva MK IV Sports Racer
    1961 Ginetta G4

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Big secret in working the British cars, contortionism and patience.
    Larry K
    58 Jag 3.4 MK 1 auto under restoration, 57 Jag 3.4 MK1 manual ,
    03 Cooper S, 2011 Cooper S Countryman, 2011 Land Rover LR4 HSE LUX, 1964 Valiant V200
    Also had , 68 Cortina 1600E, 64 Spit 4 & 80 1500, 73 GT6 3, 71 XJ6, 79 XJ6, 86 XJS V-12, 53 XK120 OTS.

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Once you get the air cleaners and carbs off, the rest is easily accessible. Be sure to keep track of which manifold nuts are the tall ones.

    Don't worry about taking off both manifolds - you'll need new gaskets anyway. I modified these cheap HF wrenches for carb nuts.

    screenshot.1647.jpg

    Notching the choke cable brackets makes them easier to remove and reinstall:
    ChokeBracketNotched.jpg
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Super! Thanks for the pics Steve. I'm off to the grinder:-)

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Quote Originally Posted by steveg View Post
    Once you get the air cleaners and carbs off, the rest is easily accessible. Be sure to keep track of which manifold nuts are the tall ones.



    Notching the choke cable brackets makes them easier to remove and reinstall:
    ChokeBracketNotched.jpg
    I tack welded nuts to my choke brackets. that not only makes the brackets easier to R&R, but the nuts too.
    John, BN4

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    I use these in my race tool ensemble to r & r the parts in question many times throughout the season.

    https://www.sears.com/craftsman-7-pc...000P?rrec=true
    Dougie
    '65 BJ8 3000 MKIII GN.29
    '57 100-SIX MM Vintage Racer GN.1 #414
    Team Healey PDX

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Ratcheting open-end wrenches can be helpful in tight spots, such as the carb nuts.

    screenshot.1682.jpg
    Steve Gerow
    Altadena, CA, USA
    Maker of most complete Big Healey rear disc kit
    Check out my galleries:
    http://www.pbase.com/stevegerow


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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Just to close out this thread...After grinding down a couple of wrenches, and a busting a knuckle or 2, I'm pleased to report that the exhaust manifolds have successfully been removed. They're off to ceramic coating 1st thing in the AM. My next project is installation of a new SS exhaust system. Any advice you all have is certainly welcome. Thanks to all for your help...and the inadvertent custom tool thread :-)

    Crispy, '67 BJ8, Portland, OR

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Quote Originally Posted by crispy View Post
    Just to close out this thread...After grinding down a couple of wrenches, and a busting a knuckle or 2, I'm pleased to report that the exhaust manifolds have successfully been removed. They're off to ceramic coating 1st thing in the AM. My next project is installation of a new SS exhaust system. Any advice you all have is certainly welcome. Thanks to all for your help...and the inadvertent custom tool thread :-)

    Crispy, '67 BJ8, Portland, OR
    Hey Crispy -

    I didn't see you were in Portland (Go Blazers) I could have set you up with everything you needed and a lift .......I'm in SW near Lewis & Clark College. My lift is still the available to you if you want PM me.

    '57 Rebuild on Lift.jpg

    '57 on lift -lr.jpg
    Dougie
    '65 BJ8 3000 MKIII GN.29
    '57 100-SIX MM Vintage Racer GN.1 #414
    Team Healey PDX

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    Crispy, befor you install the SS exhaust system, spend a few moments enjoying how beautiful it looks. If you've bought the Moss Version, it will go together without issue. I don't have experience with other brands, but I will assume they are also great. I don't want to start a kurfuffell but "Go Warriors".
    Rob Glasgow

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    Re: How to Remove the Exhaust Manifold?? (late BJ8)

    I did indeed buy the MOSS SS offering...having no experience w/it, i was a bit dubious. So, i'm relieved and pleased to hear that it is working well for you.

    Dougie, great to hear from someone in the hood!! I'm in Raleigh Hills. Let's get together and commiserate sometime soon. I'll reach out once I get her rolling again, and after my vacation...so stay tuned :-)

    Crispy, '67 BJ8, Portland, OR

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