300tdi Defender Exhaust manifold gasket

[towe0609]

Hi all - I'm planning of having a go at replacing the exhaust manifold gasket on my 300tdi Defender. I'm not very experienced with the spanners ... usually stick to changing the oil and pumping grease. I have changed rotors and replaced wheel bearings, and with some assistance changed the timing belt - all based on youtube clips and what I read here ... but my experience is pretty limited.

I've watched Land Rover Discovery 300tdi: Manifold Gasket Replacement - YouTube (https://youtu.be/kB5onEGqm7c) where the gasket is replaced without disconnecting the exhaust. Its a disco though ... can I check the set up is the same on a Defender? Will I be able to move the manifold/turbo out of the way enough to change the gasket without disconnecting the downpipe? I hope so, as I haven't ordered replacement gaskets.

Any other tips for someone with their L's on? I've already been getting some Penetrene on the studs in readiness. I ordered all new bolts, studs and nuts.

[woko]

Yes you can replace the gasket without removing the down pipe.
2 tips. The gasket needs to be cut into 3 pieces there is a service bulletin on this. Also disconnect the battery. I've seen the turbo drain tube short out on the starter.

[86mud]

Yes and there is enough flex in the exhaust to pry it away from the studs. Which gives you enough room to get your hands in there to clean up the mating faces of the head and the manifold.

Only issue I found is some studs came out with the nuts so had to sort those out then put the studs back in.

That you tube clip is what I followed.

[incisor]

Having done this multiple times in recent months I found it relatively easy to do with a couple of caveats

Make sure you disconnect the battery before you start pulling things apart

Make sure you do not bend the gasket

Otherwise it’s pretty straight forward considering you have done a timing belt, this should be a walk in the park [emoji106]

[towe0609]

Well, I got as far as taking off the inlet manifold, and once I got that far I could see that the oil leak I was chasing wasn't from the gasket - at least I don't think it was. Instead I found a turbo actuator pipe (RTC5099) in 2 pieces. I suspect that is what has been spraying oil around that side of the engine.

I replaced with some 6.3mm fuel hose - is that OK - or do I need to source some other sort of hose? It wasn't the tightest fit - I feel like something with a slightly smaller ID would be better.