P38A '95DT alloy inlet manifold

RangeRoller dt · Mar 18, 2019

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??

wammers · Mar 18, 2019

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

It's usually diesel from spill pipe.

RangeRoller dt · Mar 18, 2019

Il run it with manifold back on and plastics off to check

It's not pretty enough for my Princess

Guess it dôesnt matter which way gaskets go aslong as they are in there

RangeRoller dt · Mar 19, 2019

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

) so take your pick

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

Grrrrrr · Mar 19, 2019

+1 on telescopic magnet to catch the nuts.

Also, remember the bracket on rear bottom nut of the manifold.

RangeRoller dt · Mar 19, 2019

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

Henry_b · Mar 19, 2019

Very smart..

Better affair than the plastic one fitted to latter models.

RangeRoller dt · Mar 19, 2019

Henry_b said:
Very smart..

Better affair than the plastic one fitted to latter models.

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.

Henry_b · Mar 19, 2019

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.

It's all about Money..

Plastic is cheaper!

Datatek · Mar 20, 2019

Henry_b said:
Very smart..

Better affair than the plastic one fitted to latter models.

Plastic ones are lighter and much smoother inside.

Bagshot · Mar 20, 2019

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

That's not clean..!! Get some elbow grease on it private..!!

wammers · Mar 20, 2019

Datatek said:
Plastic ones are lighter and much smoother inside.

Yes generally betterer with smootherer flow.

RangeRoller dt · Mar 20, 2019

Has to be clean enough now its lacquered

Will have to splash out new clean gloves to put it back
In.

The casting is awful rough. I have smoothed it out a bit, particularly inside the ports

Grrrrrr · Mar 20, 2019

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

Forgot that one. I was referring to the breathers at the back.

RangeRoller dt · Mar 20, 2019

Grrrrrr said:
Forgot that one. I was referring to the breathers at the back.

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

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.

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

She is coming together now

brianp38dse · Mar 21, 2019

I think the breathers referred to are two plastic pipes with u bend on top for axle and gearbox

JohnM70 · Mar 21, 2019

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

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

Was it a Snap On bucket?

JohnM70 · Mar 21, 2019

See, they are real...

RangeRoller dt · Mar 21, 2019

JohnM70 said:
Was it a Snap On bucket?

They may have been snap-on scaffhold tubes... Ahem,
... I mean very exquisite breaker bars

RangeRoller dt · Mar 21, 2019

@JohnM70 - you mean one of these?

I honestly thought a snap-on bucket was something farmers use to feed their griffins and unicorns

P38A '95DT alloy inlet manifold

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