FITTING THE ALLISPORT EXHAUST MANIFOLD
1 The turbocharger was removed last month while changing the coolant pump (LRM August issue). To recap, we start by unbolting the heat shield.
2 With the shield off, the oil inlet and outlet pipes are disconnected, and the nuts removed from the studs holding the turbocharger to the exhaust manifold.
3 Still attached to the exhaust downpipe, the turbo is pulled away from the manifold so you can release the downpipe nuts and remove the unit.
4 Next remove the inlet manifold. The M8 flange nuts holding the manifold are released with a 13 mm socket, though they’re often found snapped.
5 The studs left in the cylinder head are unscrewed by tightening two M8 nuts against each other on the stud, and unscrewing with spanner on inner nut.
6 Here, one of the studs has been removed, showing the two nuts locked together. An alternative method is to tack weld a nut onto the stud.
7 With the exhaust manifold and all of the studs removed from the cylinder head, the mating surface is cleaned of any remaining deposits.
8 New longer studs are fitted to the cylinder head, using the same method of two M8 nuts locked together and driven by a 13 mm socket wrench.
9 All ten of the new longer studs are now screwed firmly into place and a fresh new manifold gasket has been fitted in place over the studs.
10 The original Td5 manifold (bottom) and the new improved design from Allisport Ltd with smoother gas flow lines and thicker flanges.
11 Following a little gentle tapping with a soft hide mallet, the new exhaust manifold is positioned over the studs on the cylinder head.
12 The Allisport stud kit has spacers for each stud – the overall effect is that the longer stud gives more elasticity and is less likely to fracture.
13 Some of the nuts securing the exhaust manifold are in very restricted positions. This cut-down 13 mm spanner really helps in the tight spots.
14 The new exhaust manifold does not possess provision for an EGR feed pipe. So the EGR valve is removed and replaced with Allisport’s EGR removal kit.