Exhaust Sleeve PIA ~ Rant ~ SDL

[JeffreyNMemphis]

Hello Peaches,

My 1987 SDL has an exhaust leak coming from an accordian sleeve that connects the exhaust manifolds.



The sleeve pictured above is only for reference. My sleeve has a crack where exhaust blows out of. I bought the new part # A117 142 01 59 for about $20.00. The previous owner had an indy mechanic replace his turbo charger and I suspect this part was molested then. Now comes the rant!

What a PIA!! I removed the clamps. My fearless inner child imagined that part would just fall out so I could drop the new one in; no such luck. I compressed the accordian sleeve together towards the middle only to realize that the exhaust manifolds are too close together to allow the part to escape. Reality sets in; the manifold has to be unbolted and removed to get the part off, this involves removing all the turbo plumbing that blocks access. After pulling the nuts off the right exhaust manifold, it becomes apparent that the left side must also be unbolted; there is not enough slack in the fitment of the right exhaust manifold to remove it. Apparently, the two exhaust manifolds overlap each other slightly and the sleeve coupler seals them.

I had to stop working at that point since it was dark and the mosquitos discovered my hot, juicy, deliciousness. It makes me crazy to start a job and have to stop, even for dinner. I can't work on the car again till Sunday. This job promises to take several hours optimistically, or day and night till I finish.

As best as I can tell, I have to at least loosen the left exhaust manifold but more likely remove it to separate the two pieces and free the bad coupling. In order to remove the left exhaust manifold I will have to unbolt/remove the stuff in the way. I can't see the bolts I have to remove.

PIA!! GRRR....

Anybody have wisdom and experience removing the manifolds easier, please let me know!