Exhaust System Exhaust Manifold DIY

Discussion in '7th Generation (2003-2008) [Acura TSX]' started by Chrispy, Wednesday 2nd Jul, 2014.

  1. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well I think my Exhaust Manifold is really on it way out, not only do I get the dreaded cabin smell but I also have a chirping sound definitely coming from the manifold, gets louder when I put my hand over the back over the exhaust (to test)

    I had it confirm by my local Honda dealer to that it was cracked, well I want to get it sorted,

    I had a quote of £712 parts and fitting from HH, thanks but no thanks so I'm now thinking of cracking it myself, (get it .....crack lol) trying to find a how to I couldn't find anything so this is all I have:

    Drain the cooling system
    2. Remove the plastic engine cover
    3. Remove the front section of the exhaust
    4. Remove the turbo oil feed and return pipe
    5. Remove the intake pipe and the pipe to the intercooler
    6. Unbolt the actuator
    7. Remove the manifold heat shield
    8. Unbolt the turbo water feed and unclip the water return
    9. Unbolt the turbo and remove (be warned it is quite heavy)
    10. Unbolt the manifold and remove

    Does anyone have any technical diagrams of the area I'll be working on that I could use as reference, I'll be jacking the car up on axle stands which should give me enough clearance to get underneath and sort it out, how much coolant does the CTDI hold? also what does the actuator look like :Tongue:,

    I've done work like this in the past, and from what I've seen on other forums its actually a straight forward job to do, just a bit time consuming, I have plenty of tools.

    Does anyone also know the torq setting that would be require for the manifold itself? :Smile:

    I've found the kits on ebay for around £320 genuine or I could get a third party kit for alot less, but at the same time you also get alot less in the "kit", so its going to be expensive non the less, I've phone a few local independent garages and they were a little bit hesitant to offer to do it never mind provide a quote so I'm a bit stuck really....

    Has anyone out there done this themselves? Other than draining and replacing the coolant (because I don't know how much it holds) and don't see this as being to difficult, my main worry is if I screw it up for any reason I'll have a rather sluggish car making a racket lol....

    Cheers boys.
     
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  2. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well guys and girls the chirping sound wasn't coming from the manifold, took the engine plastic cover off to rule out the injector and what to you know the fourth one along (furthest away from the oil filler) is leaking, and chirping, I can even feel the air escaping when I place my hand close to it, I hope it doesn't cost much to get it sorted :Messed:

    Do you reckon I should tighten it, one thing I didn't try is to see if its loose, the injects have been out in the last year so fingers crossed they're easy to remove should it come to that! :Tongue:

    I'll keep you posted, its amazing how one issue can lead to another ! :Messed:
     
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  3. Phil1978 Top Contributor ★ ★ ★ ★ ☆

    Phil Salisbury
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    Probably worth changing the washer, if it's blowing past the washer I doubt you'll get it to seal again, They're £4.26 each on Lings website
     
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  4. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well the engine was out and stripped around a year ago when the timing chain snapped, so Im guessing because they've disrupted the seal and not even replace it, its now loosing pressure, the question is do I do all four, they got the injectors out easily even after 10 years of use, and being that they were out last year in theory they should come out even easier! :Smile:

    Found some on eBay: HONDA ACCORD 2.2 CTDI DIESEL INJECTORS WASHERS (PACK OF 4). BOSCH COMMON RAIL | eBay

    But Im not sure if they are applicable, can't seem to locate a model number on the injectors, I'm phoning up my local engine specialists see what they say :Smile:, she runs fine and the escaping gas is only intermittent, no loss of power, sounds smooth. for now at least....
     
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  5. Ichiban Founder Staff Team

    England CJ Leeds
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    Who did you timing chain repalce bud ? as part of the timing chain kit you should repalce the injector washers.as the injector have to come out.. or they didnt not repalce it to keep cost down.

    if you car remapped?
     
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  6. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Long story short, reconditioned engine went in, that failed, so old engine was rebuilt then put in, but recon was just the block so everything from my old engine was ported across, bit of a bugger up really.

    I'm not entirely sure new seals were used, I've seen some on eBay just need to get the model of the injector to make sure they're the same, its going in the garage on the 26th, might get them to fit the new aux belt, got the part just needs fitting and I'm to lazy to do it myself!

    To be honest though it still sounds and feels fine and is intermittent, once every few days I just hear the blow by at idle. Took the engine cover off and saw a bit of sludge around one of the injectors, I hope its just the seal that's gone! :Tongue:

    I just don't wan't it to get worse! :Tongue:

    Nope car it completely standard! I would get it mapped but only if the manifold and DMF was done recently...
     
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  7. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well just an update, injector seals were replaced by my local (also a diesel specialist) and wow what a bloody difference....the blow by must of been killing my performance! felt sluggish to begin with, probably because disconnecting the battery reset the ECU.

    And best of all £60 fitted for all four! :Wink: couldn't be happier,

    So now I'm back on with the Manifold then maybe a remap....

    I'm looking to buy this HONDA Civic, UFO, ACCORD, CR-F, FR-V, 2.2i CTDI 2002-2011 NEW EXHAUST MANIFOLD | eBay and then get my local to quote to fit it, or as originally stated do it myself! Saving a few bob...

    Honda wanted £712 all in,

    So £265 for the manifold leaves £447 to play with for labour, and considering they swapped the whole engine for £600 I reckon it'll be around £200 mark, Saving me £247 in theory.

    I'm going to ring them up tomorrow for a quote,

    I'll keep you guys updated :Grin:
     
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  8. Nels Moderator Staff Team

    Great news about the seals. :pump:
    Looking forward to some good news for the quote. :Tea:
     
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  9. Doc Expert Advisor ★ ★ ★ ★ ★

    Matt Peterborough
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    I've recently had my manifold changed and although at first it may seem like a daunting job it is relatively straight forward if you are a competent home mechanic.

    It's always worth putting some lubricant on the nuts a couple of days in advance to help with their removal. But my car is 6 years old and they came off without any trouble. Just don't force them and break a stud.
     
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  10. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Still havn't phoned them up, a little skint at the moment so I will probably have to wait until next payday to actually make anything happen I'm afraid, but I will ask for a quote sometime this week :Grin:
     
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  11. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well I got a quote, and well I couldn't be happier, £168 all in for labour,

    So back to calculations:

    £265 for the manifold + £168 for labour totals: £433

    That against Honda's quote of £712 all in leaves me quids in at £279 saving.

    Not a bad result, unfortunately I can't get the part until end of this month and they can't fit me in for a few months, so its going to be end of October before it gets fitted :Smile:

    But none the less I'm a happy man! :Grin:
     
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    DeviateDefiant and Nels like this.
  12. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    Great price Chris :Thumbup:
     
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  13. Topper Harley Senior Member ★ ★ ☆ ☆ ☆

    Why not just weld the manifold.
     
  14. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Well I'd rather have the revised single piece cast as opposed to the two part cast which cracks coincidently at the welds, it would only be a temporary fix until the expand and contracting cracks the new weld and I'm back to square one, and another £140 odd labour all over again :Tongue:

    I have considered that to keep costs down but I don't think it wouldn't last as long, and I intend to run this car for as long as I can until something catastrophic occurs, but you never know engine could fall out tomorrow for all I know,

    I'm still debating if I should have it changed to be honest, £400 would look better in my savings account, as it stands car drives spot on, just smells a bit on start up, a lot less now that the leaky injector seal has been replaced. Its just in winter with the blowers on its even more noticeable.....

    :Messed:
     
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  15. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    If you can smell it, it means you're breathing in exhaust gases ! That's not good, get it sorted Chrispy.
     
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  16. Nels Moderator Staff Team

    Agree with Speedy. Exhaust fumes inside the car needs prompt action. In the meantime, I'd have the windows/sunroof open to vent the car as much as possible.
     
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  17. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Good job it isn't petrol, I would of been asleep by now, tried it on with Honda UK on the basis of "regardless my vehicle is no longer under warranty your poor design is a danger to my health, I may take it further if I have to". I got a door slammed in my face lol.... that was my last line of defence, no warranty, no deal.

    Been like it for around a year now, its not all that bad....on smells on initial start up, probably killing a bit of back pressure too, and well If I am going to the route of getting it remapped I'd be silly not to sort it out....

    Hmmmm what to do....
     
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  18. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    Get it sorted Chris, aside from the problem of fumes and a minor performance loss - looking at how you maintain the car I'm sure you don't want it hanging over your head.
     
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  19. Chrispy Senior Member ★ ★ ☆ ☆ ☆

    Chris Nottinghamshire
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    Yeaah I like to keep everything I own in tip top condition, just trying to justify the cost really :/ I will just have to put away the pennies and buy the part when I've got enough and then get it fitted, ideally before winter if I can! :Smile:
     
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  20. DeviateDefiant Co-Founder Staff Team

    United Kingdom Leo Northants
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    Yeah, I guess it's not super urgent so you have time on your side :Smile:
     
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