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jnglmstr

Member Since: 03 Aug 2015
Location: Dorking - Surrey
Posts: 14

1996 Defender 110 300 Tdi SW Coniston Green

300tdi bull horn leaking/removal

My '96 300tdi just failed its MOT on an exhaust gas leak. Turns out the bull horns leak where they enter the turbo. Oh joy.

Can they be removed in situ or am I facing the removal of the entire turbo? Any tips with regards to sealing them up? I believe they are simply pushed in?

Many thanks,
R.

27th Oct 2022 2:31pm

donmacn

Member Since: 07 Nov 2017
Location: Nth Scotland
Posts: 1829

Hi, they are a simple push in. I "might" have put a smear of exhaust sealant onto them when I fitted my new turbo and manifold, but I can't really remember.

As they fit over studs in the head, and assuming the studs stay in place (which they don't always) then I think you'll be looking at taking the turbo off - or at least pulling it back off the head.

It might be advisable anyway so that you could get a new gasket on there, on the basis that disturbing the 'old' one might make it less likely to seal on the refit.

HTH Donald

1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong
(The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html )
2000 Range Rover P38 4.0L V8

in the past..
RR classic - fitted with 200Tdi
1984 RR classic - V8 with ZF auto box
1993 Discovery 300Tdi

not to mention the minis and the Type 2 VW camper...

27th Oct 2022 7:28pm

Sharpasaspoon

Member Since: 18 Oct 2022
Location: Worcestershire
Posts: 7

Removing the turbos/manifold in one piece isn't too bad. The 3 x nuts going into the exhaust can be tight but a MAP gas or blow lamp helps. I needed 20inches of extention bars to put a good 6 sided socket on them from underneath lying on my back.

Put a plastic bag over the oil lines into the turbo to stop dirt getting in once you've removed them.

27th Oct 2022 8:29pm

donmacn

Member Since: 07 Nov 2017
Location: Nth Scotland
Posts: 1829

I wouldn't disagree with any of that, but if the issue is just the bullhorns it 'might' be possible to remove and refit them with the turbo still connected, just pulled back away from the head and tied off.

I'd agree, if the horns put up a fight then getting the whole unit off and onto a bench would be better. Donald

1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong
(The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html )
2000 Range Rover P38 4.0L V8

in the past..
RR classic - fitted with 200Tdi
1984 RR classic - V8 with ZF auto box
1993 Discovery 300Tdi

not to mention the minis and the Type 2 VW camper...

27th Oct 2022 9:26pm

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