Simple job, Exhaust leak pipe to manifold

[scot]

I have a small exhaust leak in the cat pipe to manifold connection (D I). I would just go pull it out and replace the gasket but figured its too simple, nothing could be that simple. Removing the pipe is going to cause my manifold to explode or something isnt it?

(I found the leak through my third application of seafoam. Noticed smoke in the engine bay and sure enough, it was coming out of that connection. I'll report back in this weekend on if there is really any difference in how the engine feels)

Is the gasket a LR only one or can I get one from advance/napa?

Thanks,
Scot

 

[campbell]

I replaced that gasket on my D2. No surprises, just be carefull about the bolts rusting in place. Spray some PB Blaster on them before trying to loosen them.
I bought mine from TRL since they are close to my home. Great guys also, very helpful...

 

[DiscoJen]

I got my gaskets from Motorcars LTD, I also bought a few nuts/bolts just in case one broke. I soaked the existing nuts/bolts with PB Blaster before I got started and all went very well. I had to use a big pry bar between the downpipe and the frame to get enough clearance to slide my gasket in (one of the bolts stayed on the pipe so I had to clear over it - at least it didn't break off). It was the best $4 I spent on my truck to date!

J

 

[scot]

Sounds good. I'll go stop by the LR dealership when I return from a trip to pick up that gasket.

As for the seafoam, I put in my fourth treatment (the last of the second bottle) and WOW. No the idle is not butter smoothe, nor do I now have 500+hp, but it is a little bit better. The wow is actually about the smoke. The first three treatements created a bit, but the fourth... I left it idling outside for about 15 minutes, and it was smoking so much I was worried my neighbors were going to say something. So I drove around blowing out volumes of smoke. Took over 15 miles of driving to get rid of all of it! It was pouring out at one point so thick I could only see out of half of the rear window. (I was going quite slow at the time)

Now the exhaust is clear and everything looks good. Give it a thousand miles and run another bottle through (only 1/3 pint at a time as the instructions say).


Saturday afternoon will be time to do the exhaust gasket, and the rear diff. Transmission, transfer case, engine and front diff fluids have been changed. The front diff oil was really nasty, light grey in color and the oil didnt have that super nasty smell gear oil should have.

I cant wait to see how the disco feels after getting all this done and the new tires on tuesday!

Scot

 

[rover4x4]

dont count eggs before they hatch its a Rover

 

[scot]

Well I replaced it, and it almost went well. Right up until I got a call and rolled over to grab the cell, bending part of the new gasket in the process. Bent it back and tried it anyway, but it is still leaking. Oh well, guess I will go get ANOTHER one from the dealer but make sure NOT to answer the phone this time.

To determine it was still leaking I used a bit more seafoam today and found that not only is that connection leaking, the connection on the manifold to engine is also leaking but only slightly. Specifically passenger side, exhaust opening closest to the passenger. I don't see any obvious cracks and I checked to make sure the bolts are tight. Should I just pull the manifold off and replace both of the gaskets (after checking for cracks)? Is there anything special about removing the manifold?

Will be soaked in plenty of pb blaster of course.

Scot

When its all said and done, I am really hoping my engine will stop sounding like a diesel at low throttle openings and the idle will will improve a bit.

 

[bazzle]

Im in OZ and just bit the bullet and put headers on. No more leaks or cracked manifolds

Bazzle

 

[ptschram]

To determine it was still leaking I used a bit more seafoam today and found that not only is that connection leaking, the connection on the manifold to engine is also leaking but only slightly. Specifically passenger side, exhaust opening closest to the passenger. I don't see any obvious cracks and I checked to make sure the bolts are tight. Should I just pull the manifold off and replace both of the gaskets (after checking for cracks)? Is there anything special about removing the manifold?

I have recently begun to see several trucks with breaks of the weld at the flange at the manifold. One truck even had the weld around the round cat con broken almost all the way around the cat!

The passenger side is the worst due to the shielding for the starter motor. Be careful sith the bolts toward the back. Shopboy has broken many of them, in one case, requiring pulling the head to remove the debris and to tap the hole out to 7/16-14 for a stud.

 

[scot]

How much did that header setup cost you and did you have to do any modifications to it? There are some posts about headers available here in the USA. but they require some fairly signifigant mods to make them work. (Welding new flanges/pipes to mount the stock Y pipe, or replace it with another set of pipes etc)

Notice any power increase?