Discovery 200TDI In Defender choking exhaust

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Brighty

New Member
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8
Location
Dunmow
Hi there, I have an ex MOD 90 soft top with a Discovery 200TDI engine...fine for 10 years until I replaced front down pipe and mid section..now the exhaust gives me an excruciating sore throat..even if I just move it on the drive. Definitely no leaks...I know exhaust can be drawn in the back, but I don’t even get as far as driving it and get a sore throat. New fuel filter, new air filter, at my wits end to the point of selling as worried about what it’s doing to my throat and lungs!!!
 
It’s a conversation kit from Steve Parker
Ohhh..can I have your old one then?
I need one to use as a template as I want to attempt to make one out of stainless steel. Got one on mine but it's a daily driver and I doubt I can remove it, copy it and reinstall in a few hrs.
Happy to pay.
I found its awkward to get the SP flange bolted up to the manifold square , have you got the tin gasket in place? I have heard of some SP pipes not fitting well and on mine I had to open up the holes slightly as only 2 of the 3 bolts lined up, I used bolts rather than shorter studs. Fitting the top piece then the bottom is easier as it makes the job too heavy and enlignment difficult.
You should see soot around the leak or feel it at least, feel with a cold running engine and check from the manifold first working your way down and along.
 
Thank you ...maybe I’m looking in the wrong place...have exhaust checked several times definitely no leaks...manifold gasket could be the culprit?
if you were driving id think its coming in the back it used to on mine and hence fume curtains been available, but stood must be leak
 
Ohhh..can I have your old one then?
I need one to use as a template as I want to attempt to make one out of stainless steel. Got one on mine but it's a daily driver and I doubt I can remove it, copy it and reinstall in a few hrs.
Happy to pay.
I found its awkward to get the SP flange bolted up to the manifold square , have you got the tin gasket in place? I have heard of some SP pipes not fitting well and on mine I had to open up the holes slightly as only 2 of the 3 bolts lined up, I used bolts rather than shorter studs. Fitting the top piece then the bottom is easier as it makes the job too heavy and enlignment difficult.
You should see soot around the leak or feel it at least, feel with a cold running engine and check from the manifold first working your way down and along.
Thank you so much..I’ll have a look...
 
Also worth putting your hand down the back of the cylinder head with engine running and see/feel if the gasket is blowing.
 
Many thanks..I’ll try that as well...

I should have made that more clear, I meant to see/fell if the head gasket has blown (quite common on number 4 cylinder) not the ex/intake gasket James mentioned.
 
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