Inlet/Exhaust Manifold gasket replacing

I cleaned out my intercooler and Inlet manifold yesterday and noticed my Manifold gasket has split. I purchased a new one anyway so have one ready to do the job however I've never attempted this before.

I can see a series of nuts that screw onto studs that remove the exhaust manifold. I can see around 7. Ive read on forums that you can remove the bolts then pry the exhaust away from the block and remove the gasket and swap it. However I was under the impression that the surface needs to be clean before fitting a new gasket and I cant see how it can be cleaned this way.

I also read about the studs coming loose when undoing the exhaust manifold. How would I screw these back into the block?

Is it easy to just strip the exhaust manifold back remove it, then clean all the surfaces and put it back together? Is this a big job. I enjoy learning but when I start I hate not having my car haha.

Is this a couple of hours job or a lot bigger?

Arrange a hire car for week and it all goes well, need it next day and you'll snap 2 studs and break something expensive.

Not a terrible job but if a stud does snap, it gets messy!

Well I have two hours tomorrow morning before work, I soaked the nuts in GT85 this morning to hope it frees them up. Ill give them another soaking tonight. In other words don't rush it and its simple enough?

Do I take it all apart or just prise it back?

brettguise said:

Well I have two hours tomorrow morning before work, I soaked the nuts in GT85 this morning to hope it frees them up. Ill give them another soaking tonight. In other words don't rush it and its simple enough?

Do I take it all apart or just prise it back?

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If its a 200tdi the manual states to take the turbo off too, I will be doing mine tomorrow, Its also recomended to use new studs and bolts.

It's 300tdi. I think I'm best to have a go at the bolts and see how I get on. Face the consequences if one snaps lol.

I did mine a couple of weeks ago on a disco 300tdi and it only took about 30 minutes all in.

Remove inlet manifold completely first and then remove exhaust manifold bolts.

I had about 6" to play with and cleaned the face on the block and manifolds and put back together and torqued up.

Seems like a big job, just take your time and enjoy the difference when done! B-)

Did it this morning. Complete novice mechanic I am. I had already removed the inlet manifold to clean that anyway. Took me an hr to remove all bolts clean them up, removed the gasket and cleaned the face. New gasket in and did the bolts back up. Three studs had the bolts seized so after Removing the studs I then just tightened them back up carefully. Fairly sure that will hold it in place.

After my inlet manifold is dry I will be putting that on. Total time 1hr 30 from start to finish. Even got time to walk the dog before work

brettguise said:

Did it this morning. Complete novice mechanic I am. I had already removed the inlet manifold to clean that anyway. Took me an hr to remove all bolts clean them up, removed the gasket and cleaned the face. New gasket in and did the bolts back up. Three studs had the bolts seized so after Removing the studs I then just tightened them back up carefully. Fairly sure that will hold it in place.

After my inlet manifold is dry I will be putting that on. Total time 1hr 30 from start to finish. Even got time to walk the dog before work

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Excellent job BG, well done. Was there a lot of the black tar stuff in the inlet manifold?

Dave

It wasn't as bad as I thought, I gave it a rough clean but it was only lining the inside of the inlet it wasn't too thick and hard to scrape out. I'd say the inlet may have been off and cleaned before. A lot of black come out the intercooler. After replacing a leaky bottom turbo hose into the intercooler and the new gasket and clean up hopefully it should run a little smoother. Before I put the inlet manifold back on what other pipes should I check for splits as the car and turbo sounded sluggish and the turbo was whistling funnily.

Cheers Brett.

brettguise said:

It wasn't as bad as I thought, I gave it a rough clean but it was only lining the inside of the inlet it wasn't too thick and hard to scrape out. I'd say the inlet may have been off and cleaned before. A lot of black come out the intercooler. After replacing a leaky bottom turbo hose into the intercooler and the new gasket and clean up hopefully it should run a little smoother. Before I put the inlet manifold back on what other pipes should I check for splits as the car and turbo sounded sluggish and the turbo was whistling funnily.

Cheers Brett.

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Hi Brett, you ought to check the following:

1. Turbo hoses - these have a tendency to delaminate on the inside and create partial blockages, so they need careful checking, especially the elbow off the bottom of the turbo itself. If in any doubts replace the lot and install with good quality Jubilee clips.

2. Whistling can be caused by a blown exhaust gasket, but I think you've just changed that so hopefully that cause can be eliminated.


Cheers
Dave

I have a new elbow from the turbo down to the intercooler and a new turbo to intercooler bottom pipe. I have changed the manifold gasket, the exhaust gasket I believe from the exhaust downpipe? I did that when I installed the de cat pipe.

Ill give it a quick looking over to double check, hook this manifold and pipes back up and see how it runs then.

Put it all back together however the bottom turbo to intercooler pipe slipped I hadn't tightened jubilee clip enough sorted that but also under the exhaust manifold it's smoking. I don't know if that is burning of the wd40 off the block as I used a lot to get the nuts off. Smells a bit like burning rubber. I'll post a video. Seems to be driving ok.

brettguise said:

https://www.youtube.com/watch?v=yjsrwyfKZIE&feature=youtube_gdata_player

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It's not a massive clip is it !!!


I reckon that's probably just oil/WD burning off - if in any doubt, leave it on ticker for a while. It'll burn off in about 5 mins I would think.


Dave

It's not but it's hd so it takes up mega space uploading lol. I drove to work fine I'll have a look under hood after driving home from work and see if it's still doing it. It might be in my head but it seemed smoother driving up the revs. The turbo whistle is still loud but I don't think it's a fault. I'll let you know later cheers Dave.

You sure it was the turbo whistling and not a warped exhaust manifold?

It's deffo the turbo whistling as it kicks in. I will try get a video of that at some. Point.