Need advice...exhaust problem!
 

I noticed exhaust coming from under the hood of my '87 300D the other day. I trace the leak to a flexible flange that connects the two manifold(exhaust) pieces together held by circular band clamps.It is CRACKED!:mad:
I have a parts breakdown book that shows a metal sleeve inside of the flexible peice.My question is: Do I have to remove 1/2 of the exhaust manifold to get the sleeve and flange out to replace them.I loosened both clamps and could spin the flexible peice but it seem to not want to come away from the manifold.Any tips on removal and where i could purchase these items would be helpful.
TIA. Joe.

Joe:

Just went out and looked at mine -- I don't see any way to compress that part enough to get it out, and I'm sure there is also something inside.

I'd try to take the front half off first, if you can reach the maifold bolts to avoid having to take the turbo flange off. Not much room in there.

I'm going to have to check my flex pipe (behind the turbo) for cracks -- I think the engine is too loud, with sound coming from that side.

PEter

Yes I've checked all the other flex peices.This one is the trouble area.It appears I'll have to remove the smaller of the two manifold halves to remove it.For now I put a small bead of steel epoxy around the cracked area then installed the clamp and applied more epoxy on that.It seems to be holding but definitely not permanant.I suppose I'll have to make atrip to the dealer for this one.:(

You will need to remove both manifolds to change the expansion bellows and inner sleave. The sleave fits inside the two manifolds and you need to spread them appart to get it in. The manifold bolts do not allow sufficient play to get the sleave out and the bellows installed. The only other options is to remove the exhaust manifold studs from the front section to allow you to slide the manifold forward.

henry

OK........Now where do I get the sleeve and exhaust bellows?
Here or dealer?
I too was thinking if I removed the smaller forward manifold section I could slide the bellow and sleeve out. Possibly?
Why is such a small thing SO HARD!?!?!? ARRRGH!:mad:
Thanks Guys!

You will need to get the parts from the dealer most likely. You will need the accordian sections, sleave, new clamps, exhaust manifold gaskets, new compression nuts and a lot of patience. ALso, take a look to see if the exhaust manifold is leaking, especially near the #6 area. If you have any leaks, now is the time to get it fixed. YOu will need to have the manifold machined true if it leaks. They have a tendancy to warp when they leak.

To remove the manifolds, you will need to remove the sound and heat sheild first and the EGR mount and cross tube to the turbo. You can get good access to the manifold bolts from under the car. Be carefull not to strip the nuts with an ill fitting socket or open end wrench. I found using a box wrench to break the nuts worked best. You will also need a long allen wrench to remove the nuts holding the EGR bracket.

Good luck