HELP! Why would the exhaust manifold of a 91 Chevy Blazer come off and not fit back on.?

Question

While replacing the head gasket on my '91 Chevy Blazer, I had to remove the exhaust manifold. It came off easy enough, but when I tried to place it back on, it was off almost 1/2 in. I've tried everything. Does anyone know why this would happen or have any idea how to get it back on? ANY suggestions are welcome.

Answer 1

Go to the local parts house and ask for the tool that is made for this application. Both Lisle and K-D Tools make it, and it costs < $20.00!

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http://www.toolsource.com/ost/product.asp?sourceid=googlekd&dept%5Fid=500&pf%5Fid=67711&mscssid=NRA5LQM44KP89M4A0H2W154X3NSC5MNE

Answer 2

The exhaust system is fitted w/ all the parts new and when used the manifold, and the exhaust pipe change shape somewhat because of the heat. You will need to loosen up the hangers on the rest of the exh. system. Maybe even loosen it where it bolts to the manifold itself. You may even be able to pry it into place to get one of the bolts in w/ the help of a friend. Also, when you put it all back together, us a high temperature antiseeze lubricant. This will really pay off in the future. I have been up the road you are on several times and it is frustrating. Good luck.

Answer 3

Natallbad and Ironhand are exactly right on the mark with their answers. You can take one of those things off and turn around to put it on a replacement engine and they will not fit. Get the spreader, it'll do the trick. No need to buy a new manifold unless you just like to waste money.

Answer 4

Been there and done that. The clearances are a bit tight. Take a deep breath and remove the bolts holding the manifold to the converter pipe and remove the manifold. Eye up the bolt pattern on the head and manifold and you'll find out where you're not fitting. After all, it was on once, it should go on again unless it's warped. But I've never heard of it being one inch.

Answer 5

have some one else look in there with a better light and see what you doing you could be on a wrong assessment of where you really are , the manifold could be on the wrong alignment key stud bolt you could be off where your doing the estimate but you can't really see it but you can tell some body Else what you are looking for and can they get to see it better from another spot. there should be a stud to guide you and this isn't what it should you've found the error gaskets are notorious for being cut to cover a wide variety of applications and if got hung cause of 350 327 305 302 where all one the same sheet gasket i had and were all allot to contend with for a novice
if you got the "Y" pipe and all tighten up that your problem cause its own shape from the new "Y" . if you got a jap replacement or a dead on factory part, anyway that, where you go on part for part til you get it.

Answer 6

The manifold is warped, You can either buy another manifold, or buy a tool to stretch it back in place. You can get the tools(you need a set of two) from Lisle tools http://www.lislecorp.com/tool_search_results.cfm?Search=exhaust

Answer 7

full size chevy? 5.7 liter engine? Manifolds warped common problem.Snap on tools or Matco or Mac tools sell a exhaust manifold spreader for GM vehicles.

Answer 8

Did you remove the rest of the exhaust pipe? or just unbolt it frorm the manifold? if not try doing it. when its still together the weight of the exhaust pipe can make it harder to put the manifold back on

Answer 9

Disconnect the exhaust pipe from the manifold. This will allow you to move it around more which will help.

Answer 10

these things warp. they make a spacer tool that should be put in place before you unbolt them. however if you can find the tool, it wouldn't hurt to use it to try too spread them back in shape.