924Board.org

[Nein37]

I'm pretty certain I have an exhaust leak coming from my exhaust manifold. Is it possible to remove the exhaust manifold without removing the head?
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1981 931 CGT replica, OEM CGT intercooler, .8 BAR WG spring, GTS Headlights, Innovative Wide band A/F, A/C delete, 16" Fuchs, Weltmeister 200lb lowering springs, Bilstein HDs front, Koni Sport rears.

[morghen]

yes, i've done it.

you have to take out the turbo-back exhaust..then the turbo...then it is possible to take out the ehxhaust manifold.

i have a RHD engine on a LHD car...so normally this should make this job harder....i used flexible joints to get to the nuts and bolts hidden away and all went relatively ok....just hope that you dont break any of the studs.
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Supercharger and EFI kits
https://www.the924.com

[Rich H]

It. Will. Hurt.

Good luck!
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

[Rasta Monsta]

If your car still has the factory-installed exhaust studs, I think you're better off pulling the motor. You may be looking at a busted stud, way easier to evaluate and replace with the motor on a stand. . .you may also want (or be forced) to use helicoils on reassembly, also easier on a stand.
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Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[ideola]

Before you go to the trouble of messing with the manifold, I would remove the main downpipe and inspect it for cracks at the pipe-to-turbine interface. As I'm starting to prep the club sport and remove stuff from the underside, I discovered a huge (poorly repaired) crack there that was probably 80% of the exhaust leak on that car. (The manifold has an obvious crack up top and is missing some studs, so there are other problems). But point being, if there's a crack on that pipe where it faces the block, it will be almost impossible to see unless you remove it (or a bunch of other stuff). Good luck either way.
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erstwhile owner of just about every 924 variant ever made

[Nein37]

The head was off a couple of years ago, so I'm not too worried about the studs... but I will be as careful as possible.

Dan,
I'll take that advice and check the downpipe as well.

My symptom is a rather noisey engine on cold start and as it heats up it gets quieter and quieter. After driving for an hour or so the engine sounds much better. I'm suspecting a small leak somewhere that closes up tight when fully warmed.
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1981 931 CGT replica, OEM CGT intercooler, .8 BAR WG spring, GTS Headlights, Innovative Wide band A/F, A/C delete, 16" Fuchs, Weltmeister 200lb lowering springs, Bilstein HDs front, Koni Sport rears.

[ideola]

The other obvious thing to check is the turbine to exhaust manifold union. Those fasteners are notorious for letting go. For starters, make sure you can see all three fasteners.
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erstwhile owner of just about every 924 variant ever made