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Thread: 300 tdi Inlet Exhaust manifold Replacement

  1. 29th January 2008, 09:53 AM #1
    Cool95
    Cool95 is offline Fossicker
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    300 tdi Inlet Exhaust manifold Replacement

    Got a blown exhaust manifold gasket and working on this weekend... figure I might as well put in new studs and bolts while I am at it, not sure of the size can someone help.

    The bolt between the turbo and manifold will be interesting getting a single hex 15mm 3/8 deep socket for this one....

    Any advice would also be helpful, would high temp gasket goo be required or is the gasket aluminium crushable?

    Figure I will be writing off most of Saturday afternoon even if the bolts come off ok.

    Thanks in advance
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  2. 29th January 2008, 05:38 PM #2
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    Landy110
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    I did it years ago, it's a piece of cake.
    From memory you don't even have to fully undo the bottom bolts, just losen them and remove the top bolts then lift the manifolds off and swing them away from the engine.
    You don't need to remove the turbo, just pull the manifold away from the head. There should be ample movement there.
    I wouldn't replace studs etc unless they need it, remember the Land Rover creedo, " if it ain't broke don't fix, modify, update or redesign it"
    The thing to keep in mind is that the exhaust is hotter than the inlet so the exhaust manifold expands & contracts a fair bit and in doing so tears the inlet part of the gasket top & bottom on 2 & 3 inlets.
    I carefully cut through the metal layer of the gasket with a hack saw in two places (I forget where but I think it was outside 2 & 3 exhaust ports) to prevent this from happening again. It will tear the paper between the ports rather than tering the whole gasket at the inlets.
    The cutting of the metal layer of the gasket took more time than the rest of the job.
    No need to add anything, the gasket should be good for years, mine is going strong after at least six years.
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  3. 29th January 2008, 06:18 PM #3
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    dhard
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    I have just changed mine and am not happy it is still leaking. I tried reusing the bolts but i don't think it was a good idea. Just took it all off again and to my dismay as i took the top inlet bolts of one of them stripped hav tried fixing them with thread repair but i'm not confident of that working may have to use helicoils. To top it of when i showed the mechanic i use for spare parts he made me feel as though i wasn't upto the task. This gives me the upsets me as i have done head gaskets and changed engines in other cars before so i am not a complete mechanical moron. It just seems that this bloody car has it in for me at the moment.
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