Fitting new Exhaust

[border]

Gonna fit a new Exhaust to my 200tdi. Easy job I Thought until ive been reading about getting the old front pipe out and new one in, alsorts of stories about having to remove gearbox cross member ect.
Is there a knack to doing this?? cant afford to pay garage prices, spent to much on the defender already.
Thanks

 

[jamesmartin]

it helps to jack chassis up and away from axle

 

[top drive]

Have you got the whole downpipe etc ? If so imo the least hassle option is to rmove the gearbox xmember.

Just 8 bolts and then use your lr screw jack to splay the chassis and it falls out

Although i fully accept that with some chassis removing the engine might be the better option.

 

[mikescuba]

I did mine about two years ago. I removed the gear box cross member and it went in OK. Bit fiddly removing the cross member.

 

[border]

it helps to jack chassis up and away from axle

Is this the way to do it without removing the cross member? James?

 

[Brown]

Some manufacturers offer a front pipe that comes apart, so as to minimise dismantling. But with the standard ones you have to drop the cross member and anti roll bar (if you have one). In my case the bit that took longest was getting the nuts off where the pipe fastens to the turbo housing without snapping the studs.

 

[bankz5152]

Dropping the X-Member was hardly difficult. Few bolts and a whack with a hammer and it falls off. This was one of the first jobs I did on my 90 at this point I didnt even have a tool kit and borrowed my mates!

 

[lynall]

In my case the bit that took longest was getting the nuts off where the pipe fastens to the turbo housing without snapping the studs.

Im guessing you have a disco engine? on the defender version the downpipe is just clamped to the turbo.

 

[bankz5152]

Posted in the Defender section so one would assume a Defender...

He has a point, they are studs on the turbo which can sheer rather easily. I snapped one but drilled it out and replaced with a nut & bolt.

 

[Brown]

Im guessing you have a disco engine? on the defender version the downpipe is just clamped to the turbo.

On the TD5 you get a flange with three studs and nuts on it. Yes, I've seen the clamp on earlier models. I was trying to get the nuts off without snapping the studs because to drill 'em out would have needed a lot more dismantling to get the turbo off. Once it had become clear that they wren't going to unscrew I spent a while carefully cutting and chiselling them off.

 

[lynall]

On the TD5 you get a flange with three studs and nuts on it. Yes, I've seen the clamp on earlier models. I was trying to get the nuts off without snapping the studs because to drill 'em out would have needed a lot more dismantling to get the turbo off. Once it had become clear that they wren't going to unscrew I spent a while carefully cutting and chiselling them off.

The op mentioned 200tdi in his post, hence my reply.

 

[bankz5152]

oopps! Still xmember removal is pretty simple!

 

[Brown]

Sorry, just dived in to confirm that you've got to take the crossmember and anti-roll bar off (whatever model you've got).

 

[border]

Thanks for replys.I guess the crossmember will have to come off. My engine is he Defender 200tdi NOT Discovery.
The front pipe I have seems to just push up into the bottom of the turbo with a clamp to hold it.
Don't understand about getting the studs out from turbo, do I have to do this?? or is that only for the Discovery engine??
Thanks Again

 

[lynall]

Studs only on disco 200 engine, all 300 and all td5, 200 defender is same set up as the previous 19j engine.
The def 200 front pipe also bolts to the engine block with some brackets, not fitting them means the downpipe will work its way off as the top clamp is not that great.
Item 3

 

[border]

Is this SS108161L the correct part number for bolt to engine block. Thanks

 

[lynall]

Is this SS108161L the correct part number for bolt to engine block. Thanks

No I think that the down pipe bracket to engine block bracket bolt, m6 from memory