Darned eff'n exhaust leak!!

[hbrown]

I have a 89' 240 hatch I have been driving off/on since 89'.At some point, the exhaust manifold bolt closest to the firewall broke off even with the head- it didn't give too much trouble with the stack cast manifold, but when I went with the hotshot header a while back it just blows out the gaskets pronto and then sounds like a pulp wood truck and stiffles the heck out of me with exhaust- unacceptable-I must do something about it. I attempted to address it when I did the headers but just gave up cause of no access to it to drill it, use ease out, whatnot. This sucks!!! I am gonna have to pull the freakin' head to deal with it- my question is, how much of a ***** is it to pull the head? How do I preserve the timing? Deal with the timing chain? all that crap- I haven't been into this engine before but I have built many engines and I am comfortable in attempting it. I may do a chain and tensioner, and some porting on the head while I'm in it. Anything else that would be wise to do while I'm in it? Is just getting the head off and on something that can be done in a saturday, or is it much more than that? I have the tools/skills- not worried about that- just the unknown time and aggravation factor- it is my daily driver right now.

[NateDogg]

You can do it on a Saturday if you really want to bust your ***. I'd say Saturday and Sunday just for some margin of error.

To maintain the timing chain in correct position just ziptie the chain to the links in a few positions.

You will have to remove the intake manifold so get a complete gasket set from Nissan. With the IM removed you should clean the EGR and IACV emissions sensor with carb cleaner. These are the most common sensors to get plugged with carbon.

[ddgsxr504]

I have a hotshot header as well, So to answer your question here you go.IF you plan on keeping your KA Motor then first go to the dealer and purchase all new head studs, nuts, and washers($60 or so) for the ehaust manifold. Second, go to Summit Racing.com and buy a copper exhaust manifold gasket($20-$30) This should aleviate any problems you are having!

[Dattebayo]

with these old azz engines you are gonna want to re-do the timing anyway. You know you could use this as a great excuse to upgrade your head equipment as well... With a header you now could use a little grind job on your valves and a little port matching.