Help removing exhaust manifold

wigwig · 01-28-2024, 02:57 PM

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.

Steeler · 01-29-2024, 08:14 PM

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.

wigwig · 01-29-2024, 08:18 PM

Quote:

Originally Posted by Steeler

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.

Steeler · 01-29-2024, 09:00 PM

Not exactly what you're dealing with as the manifolds go, but shows the extent of the manifold overhang to the collector flanges.

Clearancediver · 01-30-2024, 01:05 PM

https://www.pelicanparts.com/BMW/tec.../tech_main.htm

Try looking up info required there…

86Zed · 01-30-2024, 03:37 PM

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

Steeler · 01-30-2024, 06:46 PM

Might be that the M54 head sits a bit closer to the strut towers and other interferences than the S54 head

wigwig · 02-06-2024, 06:53 AM

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

01-28-2024, 02:57 PM	#1
wigwig Enlisted Member 5 Rep 35 Posts Drives: 2003 BMW Z4 3.0i Join Date: Nov 2023 Location: NC, United States iTrader: (0)	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. Attached Images
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01-29-2024, 08:14 PM	#2
Steeler Colonel 2429 Rep 2,704 Posts Drives: Built not Bought 04 Z4 VF Join Date: Feb 2013 Location: Kitchener Ontario Canada iTrader: (2)	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. __________________ W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX
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01-29-2024, 09:00 PM	#4
Steeler Colonel 2429 Rep 2,704 Posts Drives: Built not Bought 04 Z4 VF Join Date: Feb 2013 Location: Kitchener Ontario Canada iTrader: (2)	Not exactly what you're dealing with as the manifolds go, but shows the extent of the manifold overhang to the collector flanges. Attached Images __________________ W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX
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01-30-2024, 01:05 PM	#5
Clearancediver Lieutenant 90 Rep 406 Posts Drives: 2004 Z4 Join Date: Oct 2012 Location: Victoria, BC Canada iTrader: (0)	https://www.pelicanparts.com/BMW/tec.../tech_main.htm Try looking up info required there… __________________ Sent from my smart phone...
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01-30-2024, 03:37 PM	#6
86Zed Get off my lawn 932 Rep 1,159 Posts Drives: 6MT Join Date: Sep 2015 Location: USA iTrader: (7) Garage List 2023 GR Corolla [0.00] 2022 BMW X3 M40i [10.00] 2007 BMW Z4M Coupe [0.00] 2002 BMW 325xiT [0.00] 1991 BMW 318is [0.00]	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
Steeler Colonel 2429 Rep 2,704 Posts Drives: Built not Bought 04 Z4 VF Join Date: Feb 2013 Location: Kitchener Ontario Canada iTrader: (2)	Might be that the M54 head sits a bit closer to the strut towers and other interferences than the S54 head __________________ W2A Intercooled Vortech V3Si, custom ducting, Alpha N, 60# Bosch,2.62 pulley, multi port WMI, Severn Tuning(pokeybritches), Tial, magnaflow,SS race muffler, 42 design,3.91LSD, H&R, Hotchkis,ST coils,Konis, Megan camber arms, AKG SS, Nylon mounts, Poly bushings, Carbon interior, CF Aero.APEX
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02-06-2024, 06:53 AM	#8
wigwig Enlisted Member 5 Rep 35 Posts Drives: 2003 BMW Z4 3.0i Join Date: Nov 2023 Location: NC, United States iTrader: (0)	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
	Appreciate 0 Quote