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7 Series - E65 / E66 (2002 - 2008)
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  #1  
Old 07-07-2014, 04:11 PM
ssdriver27 ssdriver27 is offline
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Location: Washington
 
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Mein Auto: 2003 745LI Alpine White
anyone have a diy on exhaust manifold removal??

So I am in the middle of removing the exhaust manifolds in order to remove the cats and have the manifolds blasted and HPC coated. is there a DIY (write up or video) I am looking for any tips to make this process easier as these things are a total pain in the ass to remove on this car.

Currently I have the cat back removed, the covers and skid plate removed, and I have 2 bolts removed from the passenger side header which I had to remove the intake and expansion tank to get to and I am looking for some tips on making this easier as there is no room to get to most of the header bolts. Thanks in advance for any input or help here.

PS: once I have the manifolds finished I will post pics. I'm having the cats removed and installing O2 bungs for the post cat O2s which will remove the engine light permanently and then getting them sand blasted and powder coated with high temp HPC ceramic coating for better performance and less under hood heat.

~Guy
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2001 Camaro Z28 custom built and custom turbocharged 600+WHP @ 14PSI. (SOLD)

1996 Maxima GXE (commuter/camping/Dogs are coming with, car)

2003 745LI Alpine White
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  #2  
Old 07-08-2014, 11:44 AM
ssdriver27 ssdriver27 is offline
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Update!! I have all but 2 bolts removed on the passenger side header/manifold. I had to remove the ABS in addition to the expansion tank and I had to pry on the AC hose which runs right in the way of the header/manifold. The last 2 bolts I need to remove are the lower bolts on the 2 front header/manifold pipes. I plan to try and get to them from underneath the front of the motor from under the car. I am hoping I will not have any problems sliding it out the bottom. There is VERY LITTLE room. I am really hoping I will not have to raise the entire motor to get this done.

I am still looking for a DIY on removing/replacing the exhaust manifold/cat assembly for any helpful hints. Thanks
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2001 Camaro Z28 custom built and custom turbocharged 600+WHP @ 14PSI. (SOLD)

1996 Maxima GXE (commuter/camping/Dogs are coming with, car)

2003 745LI Alpine White
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  #3  
Old 07-09-2014, 11:17 AM
ssdriver27 ssdriver27 is offline
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Pictures of progress

Here are some pictures of my progress so far. Looks like I will have to raise the engine a bit to get the manifolds out after all. Much more of a pain then originally expected. I have 1 bolt left on the passenger side and that manifold will be out. It looks like in addition to raising the engine I may need to remove the steering linkage and hydraulic fluid reservoir to get to the drivers side manifold. what a fun job....
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2001 Camaro Z28 custom built and custom turbocharged 600+WHP @ 14PSI. (SOLD)

1996 Maxima GXE (commuter/camping/Dogs are coming with, car)

2003 745LI Alpine White
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  #4  
Old 07-09-2014, 11:49 AM
ndcsucks ndcsucks is offline
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What a chitty design...

it should be able to come out easier...
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  #5  
Old 07-09-2014, 01:22 PM
ssdriver27 ssdriver27 is offline
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Quote:
Originally Posted by ndcsucks View Post
What a chitty design...

it should be able to come out easier...
I concur. Why the frack didn't they put in some damn bolt access holes?? I actually thought about drilling my own header bolt access holes. still may. depends on how much I have to do to get to them.
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2001 Camaro Z28 custom built and custom turbocharged 600+WHP @ 14PSI. (SOLD)

1996 Maxima GXE (commuter/camping/Dogs are coming with, car)

2003 745LI Alpine White
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  #6  
Old 07-09-2014, 01:24 PM
ssdriver27 ssdriver27 is offline
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Location: Washington
 
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Is this the same process the dealer uses to change out the cats?? certainly no room to cut and replace them.
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2001 Camaro Z28 custom built and custom turbocharged 600+WHP @ 14PSI. (SOLD)

1996 Maxima GXE (commuter/camping/Dogs are coming with, car)

2003 745LI Alpine White
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  #7  
Old 09-29-2014, 09:11 AM
Tanz1 Tanz1 is offline
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Hey SSdriver27,
I need to change out my passenger side cat/exhaust manifold as well. Not much DIY out there to do this. I wanted to change out the manifold with a used one that I purchased from someone who was parting out his car. Without a lift, I think it is impossible. I don't want to pay the dealer $4k for this. If anyone knows of someone in northern NJ that can help, please let me know.
Thanks and good luck with your work!!
Mike

2004 745Li Sapphire Black

Last edited by Tanz1; 09-29-2014 at 09:12 AM. Reason: left off info
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