P38A '95DT alloy inlet manifold

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RangeRoller dt

RangeRoller dt

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Taken my manifold off to clean it all up and finally get round to changing the sensors. The small pool of wet around inj1 (people usually think this is injector leaking - no it is atomised) appears to be the broken gasket leaking the stuff you get in the intercooler as opposed to the usual spill pipe problem.

The new gaskets (stc2203) have a red ring on one side only, does this go engine side down??
image.jpg
 
RangeRoller dt said:
Taken my manifold off to clean it all up and finally get round to changing the sensors. The small pool of wet around inj1 (people usually think this is injector leaking - no it is atomised) appears to be the broken gasket leaking the stuff you get in the intercooler as opposed to the usual spill pipe problem.

The new gaskets (stc2203) have a red ring on one side only, does this go engine side down??
View attachment 172865
Click to expand...

It's usually diesel from spill pipe.
 
There's a few things to detach before you pull the manifold out.
Take the intercooler ducting off along with the plastics covering injectors and the intake pipe from intercooler. There is the IAT to disconnect and the pipe going to the MAP sensor.
There are 12 bolts holding the manifold flanges down (on mine 10x12mm 2x13mm:confused:) so take your pick :D The two at the bottom near the bulkhead I cracked off with a spanner then undid by hand. A magnet will stop you losing them and aid putting them back on.

Remove the uppermost two 13mm nuts and bolts on legs above the oil filter/dipstick. Slacken the lower two and push aside.
You can then wangle it out :)
Take care not to damage the threads or pipe across bulkhead when removing
 
There is a clip underneath the manifold that holds pipes out the way. Just pop them out.

NOTE in the picture I have blocked the inlet ports with tissue. You do not want any dust/crap going down there!

Be careful removing the old caked on gaskets ; the alloy is easily marked. I used brake cleaner with a dull scouring pad and a fine wire brush for the threads.


It is pretty enough now :)
image.jpg
 
Henry_b said:
Very smart..

Better affair than the plastic one fitted to latter models.
Click to expand...

They do look awful tatty when aged but beautiful all shiny new. She deserves it for behaving so well. :)
Cam cover will come off next oil change and have same treatment

Why dya think they changed to plastic anyhow? My theory is it's just the gaskets are more of a potch with alloy saves on maintenance schedules and are probably cheaper to produce.
 
RangeRoller dt said:
They do look awful tatty when aged but beautiful all shiny new. She deserves it for behaving so well. :)

Why dya think they changed to plastic anyhow? My theory is it's just the gaskets are more of a potch with alloy saves on maintenance schedules and are probably cheaper to produce.
Click to expand...

It's all about Money..

Plastic is cheaper! ;)
 
RangeRoller dt said:
There is a clip underneath the manifold that holds pipes out the way. Just pop them out.

NOTE in the picture I have blocked the inlet ports with tissue. You do not want any dust/crap going down there!

Be careful removing the old caked on gaskets ; the alloy is easily marked. I used brake cleaner with a dull scouring pad and a fine wire brush for the threads.


It is pretty enough now :)
View attachment 172996
Click to expand...
That's not clean..!! Get some elbow grease on it private..!!
 
Grrrrrr said:
Forgot that one. I was referring to the breathers at the back.
Click to expand...
I triple checked vehicle since you made me realise I'd forgot to mention clip under it's belly, don't seem to have anything at back of mine, no sign of any breathers :confused:

The gaskets actually had the red rings both sides and will only fit one way round due to the shape. They had a little play in the way they sat, so I wiggled them with a screwdriver to get them concentric before tightening them down entirely, from middle out in a crisscross fashion.
image.jpg

It was getting dark by time I finished potching about so in true @JohnM70 fashion - I dumped all my tools in a bucket and took some pics for you :)

image.jpg
image.jpg

She is coming together now
 
RangeRoller dt said:
I triple checked vehicle since you made me realise I'd forgot to mention clip under it's belly, don't seem to have anything at back of mine, no sign of any breathers :confused:

The gaskets actually had the red rings both sides and will only fit one way round due to the shape. They had a little play in the way they sat, so I wiggled them with a screwdriver to get them concentric before tightening them down entirely, from middle out in a crisscross fashion.
View attachment 173066
It was getting dark by time I finished potching about so in true @JohnM70 fashion - I dumped all my tools in a bucket and took some pics for you :)

View attachment 173067 View attachment 173068
She is coming together now
Click to expand...

Was it a Snap On bucket?
 
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