Exhaust Manifold Gasket on 300tdi

[Disco_owner]

I Removed the "Turbo and exhaust manifold" from side of the Block today, as I wanted to give a coat of VHT Paint:)

I Reckon it was 40 DegC outside :(I must have drank about 4 litres of water, my face is all burnt in the sun ,

that's teach me not to go out on a day like this to Work on my rovers :D



https://www.aulro.com/afvb/images/imported/2009/02/1225.jpg
Before. Cleaning.
https://www.aulro.com/afvb/images/imported/2009/02/1226.jpg
After Cleaning.
https://www.aulro.com/afvb/images/imported/2009/02/1227.jpg

now,I've looked through Rave CD I and can't for life of me find any part numbers
for Turbo Oil Pipe Gasket & Exhaust/Intake Manifold gasket.

Does anyone have a Part numbers for these 2 items?


Just as an experiment I placed tip of the Air Gun on Inlet of the actuator ,pulled the
trigger on the air-gun , good to know the wastegate actuator is working fine ,I assume compressed air operates the diaphram inside the actuator which operates connecting Rod , now I 'd like to re-adjust the length of connecting Rod to Wategate to lift the max boost to 17-18 psi , Is that how it's done , will I need unhook the pivotting Rod to the left of the pic , and shorten it ? :confused:


https://www.aulro.com/afvb/images/imported/2009/02/676.jpg

[Disco_owner]

Placing the old exhaust manifold gasket back on the manifold I noticed there is a slight mismatch on every port , the gasket had embedded trace lines on surface around the ports , so I grinded the excess away with a Dremel :cool:

This will probably do Bugger all to the over all performance of this little 300tdi motor but be interesting to see, But really interested to know if anyone has upped their boost by adjusting he length of the connecting Rod to actuator??

https://www.aulro.com/afvb/images/imported/2009/02/1199.jpg
As seen I have a couple of Ooops moments with the Dremel .:D

https://www.aulro.com/afvb/images/imported/2009/02/1200.jpg


I won't know how straight they surfaces are until I've placed a straight edge on top of the exhaust manifold.

[Disco_owner]

Is there is a special tool to tighten the Manifold studs to the heads before I bolt the exaust manifold back on the side of Block?

Edit:

Well It seems I found the answer I was looking for re: Turbo boost adjustment in this thread , "search" Button is your friend :angel:

http://www.aulro.com/afvb/technical-chatter/47042-turbo-boost.html

[Disco_owner]

Are these the correct part numbers?

Exhaust Gasket 300tdi = ESR3260
OE* IN/EXH Manifold Gasket 300tdi = ERR3785

[Disco_owner]

Turbo Oil line Gasket Part # = ERR2109

incase anyone would like the part number.:)

[MacFamily]

Are these the correct part numbers?

Exhaust Gasket 300tdi = ESR3260
OE* IN/EXH Manifold Gasket 300tdi = ERR3785
The ERR3785 is whats written on my Karcraft invoice when I did mine about 6 months ago.

Good job Disco-owner that is very clean.
I just removed the nuts pushed the manifold and exhuast to the side and fitted gasket.I also used Permatex Ultra Black Hi-Temp RTV silcone gasket maker on both head and manifold before putting gasket on and so far so good no leaks :D.

[Disco_owner]

The ERR3785 is whats written on my Karcraft invoice when I did mine about 6 months ago.

Good job Disco-owner that is very clean.
I just removed the nuts pushed the manifold and exhuast to the side and fitted gasket.I also used Permatex Ultra Black Hi-Temp RTV silcone gasket maker on both head and manifold before putting gasket on and so far so good no leaks :D.

Hi mate ;

you probably did well to use gasket marker on both heads and manifold , but I suspect it mightnot be necessary

well judging by what was there originally I couldn't see any on either head or the gasket , There hasn't been any leaks so far , just that I wanted to paint the exhaust manifold/turbo Housing with VHT ( cast Iron ) before putting it back together , how did you tighten up your head studs to the head . did you use any locktite with them?

[MacFamily]

Hi mate ;

you probably did well to use gasket marker on both heads and manifold , but I suspect it mightnot be necessary

well judging by what was there originally I couldn't see any on either head or the gasket , There hasn't been any leaks so far , just that I wanted to paint the exhaust manifold/turbo Housing with VHT ( cast Iron ) before putting it back together , how did you tighten up your head studs to the head . did you use any locktite with them?

I only used a little smear of the stuff and there wasent any on mine either, I just put some on there for good measure cause my gasket cracked front and back.I thought by putting some goo on there my prevent it splitting again.

Ive heard of guys actully cutting the gasket so they dont split there was a post on here somewhere about it.

I think only 1 or 2 studs come out when I did mine most of the nuts came off, I think. Was awhile ago memory is bad.No I didnt use any locktite but I think it wouldn't be a bad Idea i didn't think of it at the time.

[Disco_owner]

Hi Folks;

I've been waiting for over a week for VHT paint , it hasn't arrived , all other parts arrived yesterday ,so needing a set of wheels for now , I put everything back together , this morning I put the NEW Inlet/Exhaust manifold Gasket back on ,I had previously checked the exaust manifold itself with a straight edge and the exhaust manifold is warped:(

but not wanting to take short cuts and to be honest I couldn't be stuffed about the exhaust manifold being slightly out of wack ,I use a Honing stone on it's fine side and honed the surface of the manifolds, checked again with straight edge and it's still warped :( "bugger it" , so I put it all back together , now I've noticed after driving the Disco that i have lost 1-2 psi of boost ,It'll be hardpressed to push 13 pound of Boost.the car drives like a pig :( There must be exaust leaking ?:confused:

I carefully looked around the exuast manifold and the Exhaust Flange on the down pipe I noticed there is a slight bit of exhaust around the Turbo manifold when I hand operated the throttle cable , perhaps it's worse when engine is under load , but I can't see it with bonnet down , I tensioned the bolts from underneath using an extn for 1/2" drive ratchet somemore , original fitament I can see some Orange Goo or sealant , am I supposed to use the same stuff on the exhaust flange gasket to get a a better seal ???
Is there a specific orientation the gasket need to go on flange? any help would be appreciated?

I've also checked the Turbo Boost signal to compensator line to make sure it's got a good seal ,yep it was fine .

Checked the T-Piece for boost pressure to operate the wastegate . and it has a good seal , all silicone hoses are nicely tightgened with clamps . :confused: so what can it be ?


Is there not enough oil getting to the Turbo Shaft and hence it may not bee spining freely and Turbo is not giving me full 15psi of Boost , I've not adjusted or played aroung with the wastegate actuator rod :confused:

[Rangier Rover]

If it aint broken dont fix it :p. I think you should have had a crownie rather than the H20 on a hot day:p

If the manifold is leaking you will hear a tic tic or hiss.
Are the hoses on the fridge side ok. I can't think of anything else you could have disturbed to cause this:(

You need to get that rangie going:twisted:

Tony

[Disco_owner]

If it aint broken dont fix it :p. I think you should have had a crownie rather than the H20 on a hot day:p

If the manifold is leaking you will hear a tic tic or hiss.
Are the hoses on the fridge side ok. I can't think of anything else you could have disturbed to cause this:(

You need to get that rangie going:twisted:

Tony

I checked the Fridge side , no issues there , I've rearranged T-piece which may have contributed , I'm prety sure I tighteed the exaust Manifold studs enough :twisted:


oh and can't be stuffed pulling it apart again , so I'll put up with it being a Pig for now.:p

but,Seriously the Gurus have recommended to drop in and see them in person at amaroo park. :D

[Rangier Rover]

I checked the Fridge side , no issues there , I've rearranged T-piece which may have contributed , I'm prety sure I tighteed the exaust Manifold studs enough :twisted:


oh and can't be stuffed pulling it apart again , so I'll put up with it being a Pig for now.:p

but,Seriously the Gurus have recommended to drop in and see them in person at amaroo park. :D

The T- peice...... Boost copensator?

[Disco_owner]

The T- peice...... Boost copensator?

The arrangement for Boost compensator hasn't changed.


... Boost Pressure still comes out of the back of Garret Turbo ,in which there is 2 outlets , one which goes straight to Boost compensator, held together with Circlips that's clapmed nice and tight..

.. the other side of it goes to 1 side ot the T-Piece and mid section comes off which operates the Wategate actuator diaphramp and other side of T-Piece to the Boost Gauge.

but I'm not getting full 15 Psi Boost.....


I Should have left it alone ..........:bangin: but because of the worms up the preverbial I couldn't.....:p:D