How to remove exhaust manifold st215?

Hi all,



ST215 CALDINA STANDARD EXHAUST MANIFOLD ISSUE



I have just completed a cambelt and waterpump replacement - after the pump bearing failed on me.



While Im in there, I am also wanting to replace a broken exhaust manifold stud, but I have had no luck getting the manifold off...



I stripped down the heat shroud, released the exhaust flange, released the two side brackets mounting the turbo setup to the block, and the manifold bolts. I left the rubber hoses connecting to the turbo - as I only want to pull the manifold back a bit and replacement the broken stud and the gasket.



After doing this - I could only get the manifold off the head about 5mm. Upon further investigation it looked as though there is another unreachable bracket BEHIND the turbo...?



Is there any way to do this job without removing the turbo or pulling the engine out?



Or have I missed out some obvious procedure?





PLEASE HELP!!

Reply 1 : How to remove exhaust manifold st215?

Quote:

Originally Posted by TOYOTAST215 Hi all, ST215 CALDINA STANDARD EXHAUST MANIFOLD ISSUE I have just completed a cambelt and waterpump replacement - after the pump bearing failed on me. While Im in there, I am also wanting to replace a broken exhaust manifold stud, but I have had no luck getting the manifold off... I stripped down the heat shroud, released the exhaust flange, released the two side brackets mounting the turbo setup to the block, and the manifold bolts. I left the rubber hoses connecting to the turbo - as I only want to pull the manifold back a bit and replacement the broken stud and the gasket. After doing this - I could only get the manifold off the head about 5mm. Upon further investigation it looked as though there is another unreachable bracket BEHIND the turbo...? Is there any way to do this job without removing the turbo or pulling the engine out? Or have I missed out some obvious procedure? PLEASE HELP!!

Sadly my answer isn't going to be much help but my mechanic had my exhaust manifold off to replace the gasket, remove/replace the broken stud AND weld a section onto the manifold to take advantage of the spare stud hole (that Toyota started to use in engines made after 2001). The manifold was refaced also. Sadly don't know if my mechanic will tell me much as I paid him to do the job...would be kind of redundant of him to tell me how he did it. Plus we're now working on a surging issue (over 80km/h) the engine developed after the mod.



Steve



EDIT: Just remembered my mechanic said something about part of the turbo housing being integrated into the manifold, so the whole thing had to come off. This also made machining difficult as the mounts had to be customised to allow a manifold that had part of the turbo housing on it...