Re: bmw-digest V9 #2400

["David R. Lefebvre" <drl@xxxxxxxxxxxxxxxxx>]

There was one bolt that was cracked off, he couldn't get it out. Everything 
else bolted up fine, but I'm wondering whether that one broken bolt 
provided a genesis for the problems I've had.

The driveshaft also has a bad U-joint, so I'm looking at a rebuild.

The new manifold cured the noise, but we're still looking at engine codes 
1189, 1423 and 1421, which are undocumented. We also had a bad code for 
0161 which is for the O2 sensor heater, bank 2, sensor 2. If anyone has a 
good line on an OEM Siemens replacement, I would appreciate it, or the 
source of the other three bad codes.

I'm looking at a driveshaft rebuild for about $400 and after-market O2 
sensor for about $80, unless anyone had better leads. Thanks in advance.

At 09:31 AM 3/17/03 -0500, you wrote:
>David,the exhaust manifold is not aluminum. Aluminum melts at around 1220F
>and exhaust gas temperature can go over that under hard use of the engine
>(like on track).
>Also, it is impossible to weld aluminum to steel or stainless.
>May be he tought it was aluminum because he couldn't stick a magnet on it?
>My M42 exhaust manifold (headers) is made of stainless including the flange
>and the exhaust tubing also.
>
>On a side note, stainless or aluminum can be weld by a competent welding
>shop. TIG welding makes the nicest job.
>
>To prevent this to happening again? The only thing I can think of, is to
>check all the rubber supports for the exhaust system to make sure the
>exhaust line is attached solidly, and my be take a look at engine mounts
>for stiffness, to minimize engine movement under load.
>
>Hope this helps
>Michel.
>
>
>
>
>
>
>Date: Thu, 13 Mar 2003 22:48:34 -0600
>From: "David R. Lefebvre" <drl@domain.elided>
>Subject: <E36> Cracked exhaust manifold on 96 328ISC
>
>Has anyone experienced this? My immediate response was what caused this? I
>couldn't diagnose the problem, so I took it to my mechanic. He mentioned
>the manifold is aluminum and welded to an iron flange. It cracked at the
>weld. Comments?
>
>The dealer price is $400; I obtained a used pair cleaned up & ready to go
>for $140. It's hard enough to find someone who can weld aluminum on
>aluminum, so I opted for the used parts, but I'd like to prevent this from
>happening again.
>
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