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CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

1991 Defender 90 200 Tdi ST Alpine White

exhaust manifold allignment

Hi
I have had a lot of troubles fixing the leak between turbo and manifold. It appeared that the surfaces had to be machined - taking about 1,5 mm of each side. Now when I was about to fit it all again, I noticed - placing the manifoldgasket on the manifold, that the manifold appears to be shorter - and the bolt holes are a bit of center. 3 of the bolts was very bad looking when I took it of - had to redo the thread in the top. Now I am wondering if I need to buy a new manifold or machine the boltholes a bit to make it fit properly. I have a remap by Alive - but should that cause that much heat??
I have ordered a decat pipe - hoping that will keep things a bit cooler.

Best regards
Christian 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

2nd Sep 2012 10:34am

T1G UP

Member Since: 08 Dec 2009
Location: Bath
Posts: 3101

2011 Defender 110 Puma 2.4 XS CSW Orkney Grey

edited

2nd Sep 2012 10:58am

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

Some pictures
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Best regards
Christian

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

2nd Sep 2012 11:09am

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

Just a thought - could it have been caused by driving with faulty wiring to turbo?
And if I need a new manifold - is that obtainable from Ford - or is it special for the def.

Best regards
CRJ 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

2nd Sep 2012 11:20am

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

I was thinking about cutting the gasket in two - thus allowing it to fit. Drilling the holes a bit, and machine the openings in the two inlets near the turbo ( it is those two that has "warped"). That will cause the holes for the bolts to be bigger than the bolt itself - do not know if that will be a problem. Any ideas?
Still worried about what could have caused that much heat? -

Best regards
Christian 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

2nd Sep 2012 4:47pm

wslr

Member Since: 18 Jul 2010
Location: Wellington, Somerset
Posts: 581

I think it is probably a combination of things, not just one.

It is worth de-catting the vehicle, as I'm sure this alone is the biggest issue. Hot exhaust gasses can't get out past the turbocharger fast enough because of the back pressure leading into the cat and the standard exhaust system.

Now, with this, any rapid cooling (anything from water immersion to driving down a long hill with foot off the throttle for a while) will cause the manifold gasket to leak, and perhaps this is more of an extreme issue in your part of the world?

2nd Sep 2012 8:16pm

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