Exhaust manifold removal on 09 Coupe

1.8t · Oct 27, 2011

I bought set of Bellanger headers and was wondering how the stock manifolds came out? I have read on the passenger side the engine has to be jacked and the manifold removed from the top, but does the drivers side manifold come out the top as well? Seems as if the valve cover would need to come off for that to happen(I have read the valve cover must be removed on the passenger side). Can anyone offer some feedback?

mjorgensen Woodhouse · Oct 27, 2011

Better to remove both valve covers and eliminate the risk of damaging them, or the coating on the headers, this will make removing the plugs easier also. It helps if you can loosen the motor mounts and jack up the engine also to help get the passenger side out although it has been done without this.

ROCKET62 · Oct 27, 2011

Be ready for some scrapped knuckles and some cussing as the passenger side is a ******! Others have also suggested that removing the airbox can help with the passenger side and that's pretty simple to remove.

1.8t · Oct 27, 2011

So far everything has gone smoothly. The drivers side header is loose and I will pull it out tonight and then begin the war with the passenger side header lol.

Westxsrt10 · Oct 27, 2011

1.8t said:
So far everything has gone smoothly. The drivers side header is loose and I will pull it out tonight and then begin the war with the passenger side header lol.

Remember lift and tilt the engine to the side for easier removal. I also removed the valve covers and air box to make more clearance.

1.8t · Oct 27, 2011

I just got done pulling the drivers side header over lunch. Removing the valve cover made it relatively easy with some fiddling. I will be removing the airbox, valve cover, and jacking the engine on the passenger side. Will make sure to have plenty of beer upon starting the removal process on that side.

bluesrt · Oct 27, 2011

skip the beer skipp, it will make you lazy... lol

1.8t · Oct 27, 2011

Ok so the manifold is completely loose and again, it wasn't that big of a deal. However, now comes time to get it out of the car. When jacking the engine, do you jack on the oil pan? If so, where? Also, I am assuming remove the passenger side engine mount nut completely and maybe loosen the drivers side a decent amount so when you jack the engine tilts? Or do I remove the drivers side engine mount nut completely as well?

Thanks for any help!

bmw2nv2000 · Oct 28, 2011

Not sure where you place your jack but I was told to loosen the drivers side mount as loose as you can without removing the nut and remove the passenger side nut completely so you can jack that side up higher and it will make the motor tilt to the drivers side. I am doing headers soon so I too would like to know the best place to jack up the engine. I would assume a short piece of 2x4 wood between the corner of the oil pan and your jack but not sure.

Matt162 · Oct 28, 2011

I wouldn't jack it up from the oil pan, it may be strong enough but I wouldnt take the risk. Get a small bottle jack of some sort and find somewhere on the block to do it. There may be a certain place more practiced hands know about, just my .02! Good luck!

mjorgensen Woodhouse · Oct 28, 2011

Oil pan is fine, set a 2x4 across the front edge of it and you will be just fine.

bmw2nv2000 · Oct 28, 2011

mjorgensen Woodhouse said:
Oil pan is fine, set a 2x4 across the front edge of it and you will be just fine.

You mean I was right??? :dunno:

mjorgensen Woodhouse · Oct 28, 2011

Of course you were :2tu:

bmw2nv2000 said:
You mean I was right???

DaDood · Oct 28, 2011

ROCKET62 said:
Be ready for some scrapped knuckles and some cussing as the passenger side is a ******! Others have also suggested that removing the airbox can help with the passenger side and that's pretty simple to remove.

Too true. The drivers side comes out very easy, but the passenger side is extremely difficult. Good luck.

ACRsnake · Oct 29, 2011

Ooh ...bad memmories !

bmw2nv2000 · Oct 29, 2011

Crap ya'll are making me dread this mod already. Is it really that much worst than doing headers on my last gen 3? It wasnt too bad on the Gen 3.

F8L SNK · Oct 29, 2011

It's almost identical to Gen III It isn't bad, just tilt the engine on the passenger side and it goes pretty well.

X-Metal · Oct 29, 2011

i think there are some variations from car to car on the Gen 4's. ive done a couple, one went easy they other was a nightmare, and i had to push will someone pulled to get the stock manifold out.

bmw2nv2000 · Oct 29, 2011

Hey there Xmetal. I really liked my xmetal TB on my past 2 gen 3's sure wish you offered some for the gen 4's. The throttle response was just crazy with an x metal tb.

I'll let this thread know how my install goes maybe I'll have one of the "easy" cars

1.8t · Oct 31, 2011

Just got done with the removal of the passenger side and I found it very easy, almost easier than the drivers side. Only took me one hr with the header already loose and all other crap out of the way. I just jacked the engine and cut the shield after a couple of attempts of trying to get it out with the shield in tact. The dremel went right through the shield and as soon as I popped it off the header came out with no interference at all. However, my drivers side was harder than others on here had described and it took me numerous attempts and wiggling before it finally came out(with a fight, but I didn't have to cut the header shield). This probably made my passenger side easier as my engine may sit a little closer to the drivers side than other 08+ cars. Either way, to those contemplating the install, don't be afraid. This is has been one of the easiest tear downs I have done on any car thus far. Now that I have said that, the re-install will probably be a bear, but whatever lol

Exhaust manifold removal on 09 Coupe

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