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Tank



Member Since: 25 Jul 2014
Location: Fife
Posts: 429

Scotland 2004 Defender 90 Td5 HT Zermatt Silver
TD5 Manifold
The truck has a exhaust manifold issue, probably a broken stud.

Question.

Do I get the existing manifold machined and just reuse it or do I buy something like an AlliSport one for £600 +

The TD5 is tuned with a larger intercooler, EGR removed and a Stage 2 Map.

Cheers

Tank
Post #605538 28th Feb 2017 3:31pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7683

2011 Defender 110 Puma 2.4 USW Stornoway Grey
remove it, cut the webs out and then get it machined. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #605542 28th Feb 2017 3:59pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2068

2004 Defender 110 Td5 DCPU Epsom Green
Manifold warping is very common and generally caused by constant high EGTs, the Allisport is great but like you said very expensive. I wouldn't bother having one made up, chap on Landyzone did and it did not last.

There is a cheaper option

http://www.ebay.co.uk/itm/LAND-ROVER-TD5-M...XQ1ZhTev3~

Thats what I have currently fitted to my 110, hybrid turbo, map, IC the whole lot. I've done maybe 200miles since I fitted it, no leaks or issues thus far but I havnt really pushed it. From what I have read, It could be fine and last or it could warp again sharpish. Though £165 is a lot less than £600! Worth a punt imo.

If this one warps ill buy an Allisport but until then it's suitable.

I would also suggest sourcing some Wurth mainfold studs, much stronger than the original as well as longer to accept spacers (to allow for expansion without warping), but £15 not £80 like the Allisport/Alive ones... If you stick with standard studs then replace the nuts with copper flashed ones, means you can remove the manifold in the future without snapping the studs!


Dewebbed and machined flat -

Click image to enlarge


Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
Post #605543 28th Feb 2017 4:03pm
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Tank



Member Since: 25 Jul 2014
Location: Fife
Posts: 429

Scotland 2004 Defender 90 Td5 HT Zermatt Silver
Thanks bankz5152

Do I need to fit spaces to the Wurth mainfold studs and where would I get those?

Ta

Tank
Post #605553 28th Feb 2017 5:06pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2068

2004 Defender 110 Td5 DCPU Epsom Green
You dont need to fit the spacers, though they help to combat the warping. Currently looking at where to get them, as far as I have found out they are just billet ali or steel so shouldnt be too expensive.

Considering how easy it is to break the studs in the head then have the fear of drilling them out, if they are intact leave them and refit with copper nuts.
Post #605554 28th Feb 2017 5:10pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7683

2011 Defender 110 Puma 2.4 USW Stornoway Grey
is that just not a std one cut out with EGR blank? Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #605557 28th Feb 2017 5:15pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2068

2004 Defender 110 Td5 DCPU Epsom Green
Yes, just properly done. Standard manifold, dewebbed and machined flat as stated in my previous post.
Post #605565 28th Feb 2017 5:46pm
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Tank



Member Since: 25 Jul 2014
Location: Fife
Posts: 429

Scotland 2004 Defender 90 Td5 HT Zermatt Silver
Been fun so far.

Bolts on manifold (right hand side) weren't very tight at all? Loosen due to warping? Good news though, none of the studs have snapped? Think the gasket might have gone hence the noise?

Two studs in turbo snapped though, rusted and old age. One to go and think it will snap too Smile

Great job this is, loving it.

Tank
Post #605595 28th Feb 2017 7:54pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7683

2011 Defender 110 Puma 2.4 USW Stornoway Grey
Sorry i didnt see your ref to it being a std one or the above mentioned before. and still dont hence the quesiton. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #605623 28th Feb 2017 9:56pm
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Tank



Member Since: 25 Jul 2014
Location: Fife
Posts: 429

Scotland 2004 Defender 90 Td5 HT Zermatt Silver
Interesting . . . . took off two gaskets on the exhaust manifold, why were there two?

Tank
Post #605627 28th Feb 2017 10:08pm
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derbywill



Member Since: 25 Mar 2010
Location: Derbyshire
Posts: 539

England 2005 Defender 90 Td5 XS CSW Java Black
The metal gasket comprises of 2 pieces crimped together they can come apart upon disassembly.

Cheers

Will 2005 90 XS
1954 86'' Series 1 tilt
Post #605653 28th Feb 2017 11:30pm
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Tank



Member Since: 25 Jul 2014
Location: Fife
Posts: 429

Scotland 2004 Defender 90 Td5 HT Zermatt Silver
Cheers derbywill, sorry for the daft question.

Tank
Post #605700 1st Mar 2017 10:35am
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derbywill



Member Since: 25 Mar 2010
Location: Derbyshire
Posts: 539

England 2005 Defender 90 Td5 XS CSW Java Black
Your welcome but No question is a daft one! Thumbs Up

Cheers

Will 2005 90 XS
1954 86'' Series 1 tilt
Post #605745 1st Mar 2017 1:53pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7683

2011 Defender 110 Puma 2.4 USW Stornoway Grey
ok, thank for point it out, just missed it above the picture. so a std one then. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #605747 1st Mar 2017 2:00pm
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