So, I'm replacing the rear exhaust manifold on my 96 XJS.

The 15mm manifold bolts came out no problem. The 15mm bolts connecting the Downpipe to the manifold came out no problem. (You will need to get under the car and use a very long ratchet extension bar, I'd estimate a 30" should work.

The 13mm connecting the EGR tube to the rear manifold needed a breaker bar.

I found out that both manifolds need to be removed in order to get any one out. I would have ordered a second set of gaskets if I knew that would be the case.

The metal gaskets don't look particularly bad.

The gasket connecting the Downpipe don't look too bad either.

I was not aware of a metal EGR gasket, again looking good.

Should I have just replaced both manifolds at this point? Probably.

Oh, and the last manifold nut was a complete bear to remove on the front manifold....great. I ended up stripping it. Thank goodness for those bolt outs....worked like a charm!

 

Herea are the pics.

I plan on replacing all nuts with stainless steel ones, using anti seize.

Any reason to consider using a Hylomar product on any of the steel gaskets? Should I bite the bullet and order gaskets for the front exhaust manifold? I wish I knew they both had to come out. Its so obvious now....

 

Fit new gaskets! If you can get brass nuts, these are pretty good on exhaust manifolds. Just my view. Congrats on the work.
Greg

 

I came to a similar conclusion. In fact, I may as well order a front manifold now too. No reason to do this job (ever) again.

There's a big price difference between aftermarket gaskets and OEM. Sometimes it's better to spend the money, and other times, not so much.

The metal gaskets between the manifold and engine - $11 or $40?
The Downpipe gasket - $3 or $25?

The Downpipe at least has some rubber to it. The metal gaskets seem straightforward enough.

Any past experiences here on the forum?

 

I have no experience of the manifold gaskets, but they are rather crucial to not have to go back to...

If by the downpipe gasket you are referring to the crushable thick-ring shaped gasket between the manifold and the downpipe, then the OEM ones are worth it, as apparently aftermarket ones need periodic retightening. I was so advised and they have been excellent;

Greg

 

Well, I'm kind of happy I decided to order more parts. The nuts I removed at the downpipes do not appear to be the OEM copper plated locking type helicoil nut. I've ordered 4 of those.

I'm now considering whether I need to find the 14 locking manifold nuts. I assumed they were standard nuts, but I believe they may not be. Anyone know anything about these? Can I not use a spring washer? I can't find M10 lock nuts in brass. I'll likely stick with stainless?

Thanks for the words of advice on the metal/rubber donut gasket for the manifold connection to the downpipes.