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      01-28-2024, 02:57 PM   #1
wigwig
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Help removing exhaust manifold

Replacing the head gasket on my 2003 3.0i, but I can’t get enough room to slip the exhaust manifolds over the studs. Anyone have any tricks for getting these out? I bent the head shield out of the way with a mallet, but it doesn’t seem to want to go any further.
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      01-29-2024, 08:14 PM   #2
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When I replaced the OEM manifolds with tubular headers, a number of the studs wound out with the frozen nuts.
You might try (not a recommendation) double nutting the studs and try winding them out of the head. This is what I ended up doing.
Luckily I did not damage any threads in the head.

OR just remove the head with manifolds attached.
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      01-29-2024, 08:18 PM   #3
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Quote:
Originally Posted by Steeler View Post
When I replaced the OEM manifolds with tubular headers, a number of the studs wound out with the frozen nuts.
You might try (not a recommendation) double nutting the studs and try winding them out of the head. This is what I ended up doing.
Luckily I did not damage any threads in the head.

OR just remove the head with manifolds attached.
It seems like there is quite a bit attached to the underside of the manifolds, do you think that would all be able to just come off with the head? I was able to unbolt about them about a foot and a half from where the manifolds attach. I might end up trying that, I’ve moved on to removing the camshafts now while I try to come up with a solution.
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      01-29-2024, 09:00 PM   #4
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Not exactly what you're dealing with as the manifolds go, but shows the extent of the manifold overhang to the collector flanges.
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      01-30-2024, 01:05 PM   #5
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https://www.pelicanparts.com/BMW/tec.../tech_main.htm

Try looking up info required there…
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      01-30-2024, 03:37 PM   #6
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Not sure I fully understand the situation, however here is an image from when I replaced the exhaust manifolds and gaskets - removed the air pump valve and hose for clearance if I recall



This DIY may be helpful https://www.billswebspace.com/BMWZ4M...stallation.htm
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      01-30-2024, 06:46 PM   #7
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Might be that the M54 head sits a bit closer to the strut towers and other interferences than the S54 head
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      02-06-2024, 06:53 AM   #8
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Just a sort of update in case anyone has the same/similar issue, you are in fact able to pull the head and just leave the manifolds intact. I did end up snapping both of the side tensioner guides, but I think as long as you know what you are doing ( I didn’t know they were there D: ) then you should be fine
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