Cracked Manifold & Exhuast Tips

B

Bazzer79

Member
My girl's 2.0 Z4 Roadster has got a cracked manifold. I noticed the sound the other day and she confirmed that the garage identified it last time but said it wouldn't be a problem and would pass an MOT?

Presumably over time it will get worse to the point where it sounds unbearable (it already is to my ears). Surely a cracked manifold would effect an MOT on noise levels, emissions etc?

Does the 2.0 system have any particular weakspots? Is it possible to get them welded or do they have to be fully replaced? Are there any short term stop gap solutions?

Regarding the exhaust tail pipe tip, it currently has the factory oval tip. Is it possible to change this to twin tips? I noticed the backbox has two tailpipe outlets that are merged into one? Presumably, this could be done with a bit of welding, does anybody supply twin tips?

Thanks!
 
The manifold can be welded and might last as long if not longer than the problematic BMW one!

As for the exhaust tips. You have 2 pipes coming out but they are angled in towards each other. So they will need cutting off flush and new pipes/tips welding back onto the back box bulk head.
 
The engine management light comes on temporarily, although it hasn't on the few occasions when I've been in the car. I'm assuming this is to do with heat and expansion making the crack 'open up'??

I've done some further research on the net and couldn't find much. It would appear that the 2.0 manifold was a known weakness and that they are very difficult to get hold of replacements??? I haven't yet been able to establish yet if it's manifold that has the integrated Cat Conv.

My local has said it would be approx. 3hrs to remove it and that it could be welded if it's away from a joint, but that as he had to remove it, he would rather replace that whole manifold. He's coming back to me with a quote today. I'm wondering if replacement is a good idea if they're know to be a weakness, don't want to end up with the same issue a few miles further down the road.

Has anybody else had similar issues and how did you resolve?

R.e. the tailpipe tips, think I'll just try and clean/polish/restore the existing one as I'm trying to keep the costs down.

Thanks for the replies!!!
 
Are there no after market manifolds out there? Tubular stainless steel instead of cast? Just a thought as they are know to be week no point putting on on and having a similar problem later on?

As for the tips i would be happy to help in the future if you can come to me? Not sure where you live but i am near Oxford.
 
I've spent ages looking on the net and can't find many aftermarket manifolds. They're bloody expensive aswell due to the integrated CAT. I'd rather go down the weld repair route if it's feasible. Need to find a good relaible welder in West London, I'm sure there are a few.

Thanks for the offer r.e. the tips, I'll let you know if I'm interested in future.
 
:roll:
I have the same problem with the Cracked Manifold, It actually is not the Manifold that is cracked but the joint to the Catylist Converter. The manifold is SS tube,
I have discussed this with a specialist SS welder, He says the best way to repair is to split the weld Slip over a sleeve and weld the sleeve to the manifold and the converter, this will strengthen this section and it should not crack in the future
 
Had my exhaust welded by a SS exhaust fitting Garage cost me £20 with a 3 month warranty. I will let you know how it goes
 
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