TD5 Exhaust Manifold

Kiwi disco · Aug 1, 2010

Hi just suffered my latest of the common faults of the Disco 2, a squelling exhaust manifold. Turns out 2 studs sheared, anyway whilst waiting for the parts to arrive from Blighty I thought I'd ask a few questions:-
1. When I got the manifold off there were 2 metal gaskets between the manifold and the head is this normal?, because I've only ordered 1 replacement?
2. Is it recommended to replace all 10 studs? If so whats the easy way to get them out?
3. Would a high temperature RTV gasket compound be worth using when re-assembling?
Now I've just got to drill out the 2 sheared studs

sierrafery · Aug 1, 2010

Kiwi disco said:
Hi just suffered my latest of the common faults of the Disco 2, a squelling exhaust manifold. Turns out 2 studs sheared, anyway whilst waiting for the parts to arrive from Blighty I thought I'd ask a few questions:-
1. When I got the manifold off there were 2 metal gaskets between the manifold and the head is this normal?, because I've only ordered 1 replacement?
2. Is it recommended to replace all 10 studs? If so whats the easy way to get them out?
3. Would a high temperature RTV gasket compound be worth using when re-assembling?
Now I've just got to drill out the 2 sheared studs

I refitted just 1 gasket, reused the original 10 nuts.....I used a flexible tubular spanner.......for Nr.3...i dont think that will hurt, I did exacly as in the book..............but I observed that every time it coud be an easyer way(like i saw in an other post Mr.Urban Panzer found a better way to take out the aircon unit than the one from RAVE

)

Kiwi disco · Aug 1, 2010

I removed the aircon pump completely, think I might have made a bigger hole in the ozone! (it needed regassing anyway). The front and rear studs had sheared on mine so next weekends job is drilling them out.
Anyone got any thoughts on using high temp RTV when fitting the new gasket?

thebiglad · Aug 1, 2010

Kiwi disco said:
I removed the aircon pump completely, think I might have made a bigger hole in the ozone! (it needed regassing anyway). The front and rear studs had sheared on mine so next weekends job is drilling them out.
Anyone got any thoughts on using high temp RTV when fitting the new gasket?

It might be wise to check the mating surface of the manifold to see if it has warped (causing the snapped studs) permanently because if it has it will need machining flat before re-installation. It is also advised to cut out the 'webs' between the mounting holes as this allows the assembly to move slightly without permanent warpage.

Kiwi disco · Aug 6, 2010

Cheers, it was warped and is away getting skimmed now. Questions are:-
1. Has anyone used a sealing compound when re-assembling?
2. There are 7 studs left stuck in the block should I try and replace them at the risk of breaking them or leave them in?

TD5 Exhaust Manifold

Kiwi disco

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sierrafery

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Kiwi disco

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thebiglad

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