Thread: Replacing TD5 Exhaust Manifold Studs, D2

All.

Nothing worse than pulling it apart, replace the broken bits and then you snap some half broken studs that felt solid enough.

Then you can start all over again.

I have yet to do the procedure so I am not privy to costs.

i had mine done last week. cost for drive in, drive out was $300. this was manifold machined, new gasket, new studs, and a complimentary air lock in my cooling system!!!! apart from the last one, seemed like a decent price.

Replace ALL the studs...

And while your at it, de-stress the manifold webbing...

TD5 Manifold Fix

Only takes a grinder and a few minutes...

Originally Posted by WildOne

Is it common practice to replace all the manifold studs or only the broken ones? What is the best way to remove them, apart from paying somebody else to do it On that note, is it an expensive job to get done professionally.

thanks in advance for your collective wisdom.

Cheers all, Phill

Hi Phil, the link below that Tombie has put up, do that mod, otherwise you'll be doing the studs again very soon, the bigger studs are the same as a 300 Tdi manifold studs.

Originally Posted by Tombie2

Replace ALL the studs...

Originally Posted by Tombie2

And while your at it, de-stress the manifold webbing...

TD5 Manifold Fix

Only takes a grinder and a few minutes...

Also get something to monitor your EGTs, this is part of the problem!!

Baz.

Originally Posted by Redback

Also get something to monitor your EGTs, this is part of the problem!!

Baz.

On a manual, chipped TD5 D2, during everyday driving round town and highway, is there a safe working EGT limit so to speak? I have just had my exhaust manifold machined and studs fixed etc and also just had the head gasket done, all within about 4000k's of each other I have had an EGT gauge fitted to my truck for a while also but am not exactly sure what is considered "normal" operating tempsfor daily driving etc. I'm sure there are a few variables to take into account here, but any help would be appreciated so that my manifold and head gasket last as long as possible before I stuff them again

Aye, Mick

Originally Posted by MickG

On a manual, chipped TD5 D2, during everyday driving round town and highway, is there a safe working EGT limit so to speak? I have just had my exhaust manifold machined and studs fixed etc and also just had the head gasket done, all within about 4000k's of each other I have had an EGT gauge fitted to my truck for a while also but am not exactly sure what is considered "normal" operating tempsfor daily driving etc. I'm sure there are a few variables to take into account here, but any help would be appreciated so that my manifold and head gasket last as long as possible before I stuff them again

Aye, Mick

Had this conversation with guys at Highway Diesel (Diesel Injection Specialist) – all depends on where the sensor is mounted, they can advise once you know exactly where it’s fitted. Massive differences can be recorded by moving the sensor and amazingly small distance.

Originally Posted by MickG

On a manual, chipped TD5 D2, during everyday driving round town and highway, is there a safe working EGT limit so to speak? I have just had my exhaust manifold machined and studs fixed etc and also just had the head gasket done, all within about 4000k's of each other I have had an EGT gauge fitted to my truck for a while also but am not exactly sure what is considered "normal" operating tempsfor daily driving etc. I'm sure there are a few variables to take into account here, but any help would be appreciated so that my manifold and head gasket last as long as possible before I stuff them again

Aye, Mick

Also find out exactly where the EGT sensor is located with a measurement when you get temps.

Originally Posted by Slunnie

Also find out exactly where the EGT sensor is located with a measurement when you get temps.

Where the EGR pipe is connected to the exhaust is a good spot, i have mine there, i have the EMS 1 unit and this is where they recommend you put the probe, the braided wire going into the yellow thing is the EGT probe.

MickG

The max for EGTs in any conditions is 750C, the alarm on mine is set for 720C.


Baz.