TD5 Exhaust Manifold

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Kiwi disco

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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:(
 
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:(
Click to expand...

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:))

exman.png
 
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?
 
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?
Click to expand...


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.
 
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?
 
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