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[symes]

as for crack in manifold---try Frost Restoration they do stuff for that----and it works--saves lots of p*****g about

[chrisgixer]

Would metal 3.2 gaskets be better? Don't know if they would fit..? Or indeed, is it worth fitting 3.2 manifolds? (If 3.0 un available maybe)
I was going to suggest welding the crack, but would the manifold distort in the process?

Defo blowing and cracked though. So we where both right


Sorry Terry. More questions than answers. I've experienced the symptoms, but not done the repair.

Interesting notes on the studs.

The 2.6/3.2 is a better manifold and should flow better to (it does fit) but the gaskets are not interchangeable.

Welding cast iron is an art form, not easy and you need to drilling the crack ends to stop spreading first (which many dont bother with)

...now you mention it, some of our older machines at work have exposed cast iron connecting rods. Which some gorilla broke.
The resulting bodge Weald looked like boiling pigeon poop pored over a red hot hob that had run like mercury. The repair didn't hold. None of the weld had penetrated, and none of the cast iron join had melted in any way. How it lasted as long as it did was beyond me.
Sorry Terry, bad idea.

[dbug]

Can be done using specialist rods & specialist welder - probably easier to replace though

[Marks DTM Calib]

I have welded cast a few times but, it requires a high carbon rod and needs massive pre and post heat to prevent cracking.

If its a small non loaded part then drilling the cracks at each end followed by a spot weld and tap approach works well (create a small molten pool of metal and as it cools tap rapidly with a ball pein hammer to minimise stress in the joint)

[cem_devecioglu]

Since you only have one side off, there is no point putting on a 2.6/3.2 manifold because you will have an imbalance of course. You will also need to use a 2.5/3.0 gasket cos you'll have the SAI system.

If you were doing both sides, I'd say go for the 3.2 manifolds and gaskets and bin the SAI system and EGR valve completely.

how .. you can block EGR valve but cant disable it from the ECU.. only dbw ECUs dont have egr but they will require other setups.. as far as I know only in some astras it was possible to tell ecu you dont have egr

[Marks DTM Calib]

Correct Cem but you can make an EGR simulator circuit to repalce the valve with.

[cem_devecioglu]

Correct Cem but you can make an EGR simulator circuit to repalce the valve with.

I have done a "special design"    may be you will remember
 
and upto now cant see any negative side effect

[Marks DTM Calib]

But think of the benefits of replacing that heavy valve with three resistors, a diode and small relay 

[JayMV6]

Make sure you add a new "o"ring to the shopping list for the coolant pipe that comes off of the back of the block. Only cheap and I wouldn't re-use the old one. 

[sjc]

Drivers side is not hard to do, three-four hour ish job

I see it's the driver's side that's already off - how long to do the passenger side?  Easier or harder?

[Marks DTM Calib]

Drivers side is not hard to do, three-four hour ish job

I see it's the driver's side that's already off - how long to do the passenger side?  Easier or harder?

The hard thing about the passenger side is that all the work needs to be done whilst lying on your back

[cem_devecioglu]

Drivers side is not hard to do, three-four hour ish job

I see it's the driver's side that's already off - how long to do the passenger side?  Easier or harder?

some may not agree, but if there is a lift handy I would take out the engine (instead of changing those seperately) and do many other jobs at the same time as those are old cars anyway.. so you wont need to work under the car over and over.. 

[sjc]

Drivers side is not hard to do, three-four hour ish job

I see it's the driver's side that's already off - how long to do the passenger side?  Easier or harder?

some may not agree, but if there is a lift handy I would take out the engine (instead of changing those seperately) and do many other jobs at the same time as those are old cars anyway.. so you wont need to work under the car over and over..

Yeah, engine comes out fairly easily once you get the radiators out.  I only put the coolant one back and ditched the AC.

[Shallow Al]

as for crack in manifold---try Frost Restoration they do stuff for that----and it works--saves lots of p*****g about

The JB weld stuff?
Have you used it? Any good?

[terry paget]

Make sure you add a new "o"ring to the shopping list for the coolant pipe that comes off of the back of the block. Only cheap and I wouldn't re-use the old one. 

Thanks. I did not know it was an O ring. The pipe was stuck on the head and took some prising off. It was a nightmare getting the screws off; goodness knows how I shall get them on again.