200Tdi Discovery Exhaust clamp

bill_gj · Apr 21, 2010

Looked through the forums but couldn't find an answer, so......

Trying to fix an exhaust leak on my son's Disco 200Tdi - it's the joint between the turbo outlet elbow and the exhaust downpipe.
I can't believe what a crap piece of design it is, or - has someone fitted the wrong parts?
It just won't seal and I can't see how it would - if someone could tell me what the joint should look like I'd be grateful.

The downpipe has a sort of double sleeve which apparently is supposed to slide over the turbo outlet elbow - one sleeve goes inside the elbow and the other outside - and the downpipe is then clamped onto it using a large U-clamp (like you'd have on a silencer to tailpipe joint...but bigger).

Does that sound right?

Pikey · Apr 21, 2010

Yup but be aware that there is 2 different lengths of down pipe. fit the long one in place of the short one and it will pivot the exhaust up forcing the back box into the rear boot floor. Where it will rattle like buggery. fit the short one where you need a long one and the bugger won't reach the manifold properly.

landy.man · Apr 22, 2010

bill_gj said:
Looked through the forums but couldn't find an answer, so......

Trying to fix an exhaust leak on my son's Disco 200Tdi - it's the joint between the turbo outlet elbow and the exhaust downpipe.
I can't believe what a crap piece of design it is, or - has someone fitted the wrong parts?
It just won't seal and I can't see how it would - if someone could tell me what the joint should look like I'd be grateful.

The downpipe has a sort of double sleeve which apparently is supposed to slide over the turbo outlet elbow - one sleeve goes inside the elbow and the other outside - and the downpipe is then clamped onto it using a large U-clamp (like you'd have on a silencer to tailpipe joint...but bigger).

Does that sound right?

Yes, although I wonder if its only the OE pipe which has the double skin arrangement? The big U clamp has been "added", the proper clamp is a more slender thing, the trouble with the clamp you've got (M10 thread, 17mm nut I bet) is there's not much clearance between it and the bulkhead.

I did had problems with the original downpipe keep falling off, just do up your clamp very tight. I've had less problems with my (inferior?) single skinned aftermarket downpipe too.

bill_gj · Apr 22, 2010

Redhand - thanks for that - I didn't know about two different downpipes but it makes sense as it took two of us to get the pipe on and it still seemed short-ish.
How do you get the longer one? Was it early/late model?

LandyMan - Quite right, big nuts (oo-err) and close to the LH side rail. So it's a useless design all round then, straight from the factory?

landy.man · Apr 22, 2010

bill_gj said:
LandyMan - Quite right, big nuts (oo-err) and close to the LH side rail. So it's a useless design all round then, straight from the factory?

It works ok with the proper clamp. Trouble is yours has had a universal clamp fitted (like I had to), and these are bulkier and don't grip as well. The rest of the exhaust has to be fitted correctly too, if its pulling too hard on the pipe that won't help.

Try undoing the downpipe from middle box. That way you can trial fit it up to the turbo outlet, at least that way you can make sure the joint fits right (eg pipe could be damaged) without having the weight of the whole exhaust swinging on it.

bill_gj · May 4, 2010

Hi landy.man - We tried that one (disconnecting the next joint along) and the bugger still leaks at the turbo elbow to downpipe. Grrrrrrr.

Like I said at the top - crappy design more suited to a Fiat 500 than Discovery.
Think we might take the turbo elbow off and see if we can make something better to hold the joint together. It's a pity it's not designed the same way as the downpipe-to-silencer joint -- one of those spherical connections.

200Tdi Discovery Exhaust clamp

bill_gj

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Pikey

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landy.man

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bill_gj

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landy.man

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bill_gj

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