Td4 Inlet Manifold SPLIT!

Hi,

Three weeks ago my wife decided to buy a 2003, Td4 Freelander. It hadn't been serviced very well. Blue smoke on start-up, black smoke and loss of power on the hills (Which are plentiful around here!)

So, I have given her a full service (all filters and oil), cleaned out and checked intercooler hoses, checked the VNT mechanism and all vac lines. Removed and bypassed EGR, and a new maf (Not a genuine though but made a difference in low rev range!)

Black smoking still on hills with quick flash of the MIL. No more blue smoke.

So today I got the wife to rev the engine to 2750 (ish) rpm so I could check the hoses again as slight weeping of oil has come back on the long pipe. I could hear a gushing of air when revving but the pipes were! Turns out, it's the inlet manifold which has split! Along the front edge where it was welded.



It has also started to separate along the side for about an inch but no leak as yet! I'm assuming I may of been the MAP sensor which has failed allowing excess boost to build and split the mani.

Has anyone else suffered something alike? I've searched but nothing comes up regarding the actual manifold splitting.

Whats the chances of using something like brake cleaner to clean the egde up, sandpaper to roughen it and JB Weld to seal it?

Or buy a replacement manifold?

Cheers,

Dan

If its aluminium just weld it again

Dr_evil said:

If its aluminium just weld it again

Click to expand...

It's made of plastic.

what a terrible design........

Tell me about it!

I've cleaned it with brake cleaner, sanded it back to roughen up and them applied quick steel to fill the void, let that dry, then I smothered it with jb weld top to bottom to give it some strength.

Even if it last for 15 mins, it will be enough time to tell if the car stops smoking and pulls better. Plus the MPG is really poor!

Need to test my VCU I think.

Dan

hi

have u replaced ur crankcase filter at all, there is a bmw conversion u can do, just by the air filter, there are parts number and pics etc if u do a search on here

i think u can pick one of them up on ebay i expect

I would replace that as it does not look good and as said replace the crankcase filter, a blocked up one can course pressure which looks as though it is happening and also takes more fuel

although the crankcase filter can cause pressurisation, I don't think it would do that to the inlet manifold, it would be more likely to blow the oil dipstick out.

Plastic manifolds are known to have their quirks. Some suck themselves inwards. And some split..... You need a new one as it will never repair properly and will probably have air leaks causing poor running.

Looks like a c**p deign to me, probably just warped with heat and broken the seal. If its plastic some superglue might answer the questions you raise - but looks like it needs replacing.

In hijack mode, do people recon this could be welded (old fashioned Series Iron)...

Yes I've already replaced the crankcase filter. Not with a BMW one as yet as I got the foam one as part of a service kit. I will replace the manifold. But hopefully a temp fix will show if this has been the root cause of poor power and turbo boost.

Cheers.

Dan

Just seen this Grumpy that will weld no problem

You want some cast iron welding rods ? I've got a few here


However you will need to preheat the part (a BBQ is excellent) then weld, cool in a bucket of sand and finally peen the crap out of the welds

Thanks guys. I don't have any welding kit/experience - so would take it to a shop to get done - so was after some heads up in case the shop says 'yeh' but really its a 'nah' and I should search for a replacement.

I do have a spare engine - but the 'elbow' on that manifold pokes down rather than up - so obviosouly won't mate up with the down pipe. Unless of course its the same just mounted the other way round - don't know if that's possible - haven't checked yet.

Of course as I'm now renovating a Series truck, I should get myself a welder and get into it. If I do I might take you up on your offer Dr Evil - whats the nearest airport to you that Singapore Airlines or Emirates fly into?

Manchester I'd presume, I'll be working in Crewe for the next year so thats not far from it if you're planning on visiting the UK and want a handful of them

Not been to Singapore in ages I do miss the place

splitting manifolds is not so unusual - check out some BMW forums

A new one is expensive though i believe !!!

Maybe the scrappy is the best place to go for a replacement