405 S2 8v Exhaust Manifold Removal
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  1. #1
    1000+ Posts Pug_405_Mi16's Avatar
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    Default 405 S2 8v Exhaust Manifold Removal

    Hello All,

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    So I decided to have a go at changing the blown exhaust manifold gasket on the S2 405 tonight.

    I've ran into a bit of a problem, I have got the air cleaner/rocker cover off and can obviously access the bottom bolts the problem I have is accessing the top bolts on the manifold. I don't seem to be able to get the heat sheild off and infact it looks like it goes down behind the manifold making access to the nuts impossible.

    Can anyone give me some pointers please? As I said the car is a Series 2 8 Valve 405.

    Cheers
    Ben
    1989 Peugeot 405 Mi16
    1990 Peugeot 505 GTD Turbo Wagon
    2000 Peugeot 306 XSI
    1973 Peugeot 504 GL





  2. #2
    1000+ Posts Pug_405_Mi16's Avatar
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    Ok, so I managed to get the manifold off this morning with some more perseverance.

    The issue I now have (which was causing the blow) is the head has 2 broken studs in it, they are the top and bottom stud at the coilpack end of the motor. The question I have is, is it possible to get the broken studs out in situ or am I destined for pulling the head off?

    Any help would be much appreciated

    Ben
    1989 Peugeot 405 Mi16
    1990 Peugeot 505 GTD Turbo Wagon
    2000 Peugeot 306 XSI
    1973 Peugeot 504 GL





  3. #3
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    Need to pull the head off and accurately drill out the studs, either with a special machine or make up a jig from thick steel plate with holes at the correct spacings. You may need to use masonry drills if the studs have hardened. If you send the head over I have a mate experienced in doing this.
    Maybe try some high temp sealant first?
    In case anyone has a 403 head with broken bolts for the inlet plate I do have a jig to use to drill them out.
    Graham.


    Quote Originally Posted by Pug_405_Mi16 View Post
    Ok, so I managed to get the manifold off this morning with some more perseverance.

    The issue I now have (which was causing the blow) is the head has 2 broken studs in it, they are the top and bottom stud at the coilpack end of the motor. The question I have is, is it possible to get the broken studs out in situ or am I destined for pulling the head off?

    Any help would be much appreciated

    Ben

  4. #4
    1000+ Posts Pug_405_Mi16's Avatar
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    Thanks Graham,

    Had a bit of a go but sadly 1 of the other holes in the head was stripped out as well so too far gone, looks like the head is coming off...yipee.

    Thanks again!
    1989 Peugeot 405 Mi16
    1990 Peugeot 505 GTD Turbo Wagon
    2000 Peugeot 306 XSI
    1973 Peugeot 504 GL





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