Disco 2 Alisport Manifold

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RustySkull

RustySkull

Active Member
Posts
166
Location
Stanford-Le-Hope, Essex
Morning you lot,

I'm just wondering if any of you have wondered why Alisport have made their manifold so hard to change the oil filter. I have A/C and you can't get the lid off the centrifugal filter. You have to remove either the turbo, or the manifold and A/C. It's a bit of a pain every 3,000miles for a simple service ain't it lol.

I suppose I'm the only one that's thinking it's a bit of a bad way to make it?
 
RustySkull said:
I know! If it wasn't that that oil filter thing it would be great...
Click to expand...


I have found/seen the longer the branches the more lileys they are to crack.
On the plus side the fixing bolts have the spacers which should allow the manifold to shuffle around a bit.

Bloke i know bought some stainless one, and reckoned it was the nuts until it warped:D
 
sierrafery said:
That oil filter thing is more than enough to ruin all the joy of having such nice manifold IMO... your post saved me from a such frustration, thanks
Click to expand...
I might upload a video to YouTube to show how it is.

lynall said:
I have found/seen the longer the branches the more lileys they are to crack.
On the plus side the fixing bolts have the spacers which should allow the manifold to shuffle around a bit.

Bloke i know bought some stainless one, and reckoned it was the nuts until it warped:D
Click to expand...

I know dude, They made it really nice, and it works amazingly but that little detail with the filter is a massive issue I'm surprised there isn't more threads about it on here? I couldn't find any anyway...
 
Can you get to the bolts at all?
If you can then maybe it would be worth fitting bolts from below so you only need to get the nuts off the tops. Maybe that'd give you the necessary room. The holes the bolts thread into strip their threads for a pastime anyway!:( That way you could remove the bolts and more ore less slide the filter cover thingy nearly sideways.
If you can't I'd consider slotting the webs on your normal manifold and enlarging the studholes on the it too, especially the outer ones, to ensure it doesn't warp.
Best of luck!
 
Stanleysteamer said:
Can you get to the bolts at all?
If you can then maybe it would be worth fitting bolts from below so you only need to get the nuts off the tops. Maybe that'd give you the necessary room. The holes the bolts thread into strip their threads for a pastime anyway!:( That way you could remove the bolts and more ore less slide the filter cover thingy nearly sideways.
If you can't I'd consider slotting the webs on your normal manifold and enlarging the studholes on the it too, especially the outer ones, to ensure it doesn't warp.
Best of luck!
Click to expand...

I'm afraid nothing you said made any sense to me..

The problem with the Alisport manifold is that you can just about get to the bolts on the filter cover, but the Turbo is half a mm away from the cover because the manifold brings it that close and also the manifold itself is a few mm from the top of the cover so you can't take the cover off lol. Seems daft to me, it makes a 10 minutes service job a much longer and painful task. Especiually when rusty Turbo bolts snap off like mine did.
 
RustySkull said:
I'm afraid nothing you said made any sense to me..

The problem with the Alisport manifold is that you can just about get to the bolts on the filter cover, but the Turbo is half a mm away from the cover because the manifold brings it that close and also the manifold itself is a few mm from the top of the cover so you can't take the cover off lol. Seems daft to me, it makes a 10 minutes service job a much longer and painful task. Especiually when rusty Turbo bolts snap off like mine did.
Click to expand...
Right, the reason it made no sense must be because the new manifold is so much bigger and so much closer to the centrifugal oil filter that you simply can not take the bolts out and lift it off. even if you make the mod i suggested. I have never seen such a manifold. I'd be tempted to ask Alisport how you are expected to do that job with their manifold in place.
Did you understand about the mods to the normal manifold? And the reasoning behind them/need for them? Or is this why you want to change it?
How much extra power do you expect to get just by changing it? And are you having to change the intercooler and turbo to benefit from it? Or is it vice versa?
 
Stanleysteamer said:
Right, the reason it made no sense must be because the new manifold is so much bigger and so much closer to the centrifugal oil filter that you simply can not take the bolts out and lift it off. even if you make the mod i suggested. I have never seen such a manifold. I'd be tempted to ask Alisport how you are expected to do that job with their manifold in place.
Did you understand about the mods to the normal manifold? And the reasoning behind them/need for them? Or is this why you want to change it?
How much extra power do you expect to get just by changing it? And are you having to change the intercooler and turbo to benefit from it? Or is it vice versa?
Click to expand...

Haha yeah I understood what you were saying but I didn't see why lol.

My standard one warped that's why I bought the Alisport one. No other reason really.
Obviously the better running etc but I needed a new manifold and thought I'd go for it.

I've filmed part of a video, rest will be finished soon ans you'll see what it's like. I've had this on for a year, only just hit 3k miles to do a service and noticed the problem lmao.
 
RustySkull said:
Haha yeah I understood what you were saying but I didn't see why lol.

My standard one warped that's why I bought the Alisport one. No other reason really.
Obviously the better running etc but I needed a new manifold and thought I'd go for it.

I've filmed part of a video, rest will be finished soon ans you'll see what it's like. I've had this on for a year, only just hit 3k miles to do a service and noticed the problem lmao.
Click to expand...
I think I posted a thread about my nightmare with the warped manifold, if not I posted on somone else's. So you will find threads on it.
But to cut to the chase, if you are lucky enough to take it off without too much trouble, you can get it skimmed flat them slot the webs and drill out the studholes on cylinders 1 and five by a 1 to two mil and the ones on 2 and 3 by .5 to 1 mil then put it back on.
The nightmare is studs that pop out taking the thread with them, or nuts that will ot come off the studs and thenn you risk damaging the threads in the head as they come out with the stud, or worst of all, studs that snap off, frequently just below the top of the hole in the head. I had a mixture of these.
A skim shouldn't cost you more than £30 plus VAT, or £60 if they have to take a lot off, which was my case.
Best of luck!
 
Ive got one en route as well. However will be matched with a new VNT. Its already a pain to do my rotor filter due to the threads shearing on the housing

Every 3k seems excessive though!
 
Stanleysteamer said:
I think I posted a thread about my nightmare with the warped manifold, if not I posted on somone else's. So you will find threads on it.
But to cut to the chase, if you are lucky enough to take it off without too much trouble, you can get it skimmed flat them slot the webs and drill out the studholes on cylinders 1 and five by a 1 to two mil and the ones on 2 and 3 by .5 to 1 mil then put it back on.
The nightmare is studs that pop out taking the thread with them, or nuts that will ot come off the studs and thenn you risk damaging the threads in the head as they come out with the stud, or worst of all, studs that snap off, frequently just below the top of the hole in the head. I had a mixture of these.
A skim shouldn't cost you more than £30 plus VAT, or £60 if they have to take a lot off, which was my case.
Best of luck!
Click to expand...

Ok, still don't see why skimming it and playing around with holes and studs would fix the problem lol. The manifold is made to fit too close to the filter cover.

Thanks for your imput, I'm slightly lost though. I Know you're talking about the standard manifold, but that's long gone. Scrapped it last year lol.
 
RustySkull said:
Morning you lot,

I'm just wondering if any of you have wondered why Alisport have made their manifold so hard to change the oil filter. I have A/C and you can't get the lid off the centrifugal filter. You have to remove either the turbo, or the manifold and A/C. It's a bit of a pain every 3,000miles for a simple service ain't it lol.

I suppose I'm the only one that's thinking it's a bit of a bad way to make it?
Click to expand...

Is it worth mentioning it to the manufacturer ?

I mean, if we don't tell 'em whats wrong they aren't gonna change it ... just be left wondering why everyone stopped buying them ...
 
RustySkull said:
Ok, still don't see why skimming it and playing around with holes and studs would fix the problem lol. The manifold is made to fit too close to the filter cover.

Thanks for your imput, I'm slightly lost though. I Know you're talking about the standard manifold, but that's long gone. Scrapped it last year lol.
Click to expand...
AHHHHH! Right!!!!!!!!!!!!!!!!!
I WAS talking about a standard manifold, thought you still had it!! lol!
So that doesn't sort you out, unless you get an old standard one from a scrappy or even a new standard one and then modofy it, put it on and flog the Alisport one on! which you won't do. So I suppose you just have to take it off every time you want to sertvice the car which is blood stupid. I take it Alisport have no answer to that!
Without opening the bonnet I have no idea what the centrifugal filter is attached to and whether or not it would be possible to take THAT off. It would sure as sh!t be awkward to do and probably entail gaskets and maybe an oil change so.....? Dunno!
 
bankz5152 said:
Ive got one en route as well. However will be matched with a new VNT. Its already a pain to do my rotor filter due to the threads shearing on the housing

Every 3k seems excessive though!
Click to expand...
Threads shearing? Me too, solution is longer bolts and nuts on the bottom, or top if you invert them. Bit fiddly but not impossible and hey, Fiddly? It's a Disco!;) Must admit 5k will do me!
 
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