200tdi ‘that’ exhaust to block bracket

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JokerUK

JokerUK

Active Member
Full Member
Posts
138
Location
Calne Wiltshire
Hi all,
Having rebuilt my 200tdi engines and put a whole new exhaust on having discovered the previous one was a collection of original ‘87 tdi parts with more holes in than a holy thing (how did it get through those last MOTs?)

Anyway, I digress! Before the rebuild I was continually irritated by exhaust slippage at the manifold to down pipe joint but assumed I would fix at some point. Well that point has arrived, and I discovered the missing downpipe to block bracket ESR266 however, I’ve failed twice to buy the correct bolts/screws to mount the bracket to the block. The magic book of parts suggests SS108161L and SH110141L but having in theory purchased those bolts they don’t fit and are either too big or two small for the threaded holes (one of which is larger than the other)

I would be eternally grateful for a steer from someone towards exactly what I need to order and where to get it from.

all help gratefully received

regards

steve
1987 110 200tdi
 
I got fed up with the exhaust slipping on my 200 but decided the missing block bracket was to much of a faf to fit.
Fitted a new exhaust clamp on the manifold done up good and tight and it has stayed put.
I think getting the down pipe on first and then when doing up the next connection try to do so that it is not putting/pulling a down load on the manifold pipe helps. An 87 exhaust would be a turbo diesel system.
 
I had the same slippage and fitted the bracket.
I fitted
New exhaust downpipe (ESR158) and retaining strap (ESR266) and clamp (NTC3608) fitted

I used my own nuts and bolts (have a giant box of assorted new ones) sorry I can’t remember what sizes but they were all metric (I think the strap to exhaust bolts were actually cap head Allen bolts?)

I recall cutting them down as the holes are blind. 4 bolts iirc, 2 smaller ones that go
into captive nuts on the strap itself and 2 larger ones that go into the block (I recall these were different sizes?).

Was a bit of a faff and I *think* I bolted the strap to the downpipe first then to the block but I recall I could barely turn a ratchet spanner - it was literally 1 click of space to move in so took ages to wind the bolt in. I also recall cutting down an Allen key to fit but can’t remember why? There are definitely spanner clearance issues though on some of the bolts.

Oh and I remember I had to start the bolt through the ring spanner then orientate the spanner onto the bolt as there wasn’t space to fit the ring spanner between the bolt head and the vehicle body with the bolt not wound in a few threads.

however I have had no slippage since and just use the OEM style clamp at the top of the exhaust, it seals better to.l so was worth the effort.
Fit and tighten the exhaust manifold clamp after you have the bracket in place and tightened down.
 
What you have bought is an M10 and an M8 bolt.
I do hope you didn't buy these as Original parts ...

So when you say 'they don't fit' what do you mean exactly ?
Is it that the M10 is to big and the M8 to small or do they fit in the holes but only tighten by 1/2 a turn ?
Or are they to long or to short ?

EBay is your friend here or a good (old fashioned) hardware store.
Try a 3/8" UNF bolt (actually its a Hex Head Set Screw).
Buy stainless if you can, you should be able to get 2 or 3 for less than a quid each.
Stainless is easy to cut (with a hacksaw) .... welcome to the start of your useful nut and bolt collection :)
 
tottot said:
I got fed up with the exhaust slipping on my 200 but decided the missing block bracket was to much of a faf to fit.
Fitted a new exhaust clamp on the manifold done up good and tight and it has stayed put.
I think getting the down pipe on first and then when doing up the next connection try to do so that it is not putting/pulling a down load on the manifold pipe helps. An 87 exhaust would be a turbo diesel system.
Click to expand...
Yes, it seems quite a faff. I found my trolley Jack under the down pipe where it sweeps under allows me to get it back into position, it now no longer has a td exhaust -I’ve fitted a full 200tdi system
I think I’ll order a new manifold bracket as well as the old one is …old

I will persevere and try to get the lower bracket fitted, just need to get the right bolts
 
They are difficult to fit but go in with a little patience & be sure to lube the threads too.

@JokerUK , fit as follows:

  1. fit downpipe to manifold using exhaust sealant and nip up exhaust clamp tight enough to just hold in place
  2. fit bracket and loosely tighten
  3. fit remainder of exhaust system
  4. fully tighten downpipe bracket and manifold clamp
  5. fully tighten remainder of exhaust system
note: the downpipe upper flare sometimes needs opening/fettling to ensure a proper fit to manifold
 
miktdish said:
What you have bought is an M10 and an M8 bolt.
I do hope you didn't buy these as Original parts ...

So when you say 'they don't fit' what do you mean exactly ?
Is it that the M10 is to big and the M8 to small or do they fit in the holes but only tighten by 1/2 a turn ?
Or are they to long or to short ?

EBay is your friend here or a good (old fashioned) hardware store.
Try a 3/8" UNF bolt (actually its a Hex Head Set Screw).
Buy stainless if you can, you should be able to get 2 or 3 for less than a quid each.
Stainless is easy to cut (with a hacksaw) .... welcome to the start of your useful nut and bolt collection :)
Click to expand...

I got two bolts, prob M10 and M8 - I will need to check, but assuming I wasn’t being a complete………the M10 was too large for the larger hole and ‘I think/thought’ the other bolt was too small for the other hole.

I did subsequently clean the threads with some taps which screwed in relatively easily and didn’t feel like they were creating new threads.

I will persevere- I’m not getting the feeling that I’m missing something and so I just need to check the bolts I have and as you suggest maybe get som SS ones - and do some hack-sawing :)
 
Are they not standard metric size bolts? I seem to remember just cutting down some bolt I had lying around.

it’s a PIG to get it all connected. I had to use a ratchet strap to pull the whole exhaust backwards.
 
v8250 said:
They are difficult to fit but go in with a little patience & be sure to lube the threads too.

@JokerUK , fit as follows:

  1. fit downpipe to manifold using exhaust sealant and nip up exhaust clamp tight enough to just hold in place
  2. fit bracket and loosely tighten
  3. fit remainder of exhaust system
  4. fully tighten downpipe bracket and manifold clamp
  5. fully tighten remainder of exhaust system
note: the downpipe upper flare sometimes needs opening/fettling to ensure a proper fit to manifold
Click to expand...

…and I probably did it all in the wrong order as….
1. Once the engine was fitted I was reattaching the down pipe and noticed it had a hole at the bend so…
2.ordered a new 200tdi downpipe which didn’t align with the rest of the (unbeknownst to me) tdi system so
3. Ordered the rest of a 200 tdi system which didn’t align with any of the hanging brackets (for above reason) so
4 ordered a set of 200tdi hanging brackets and…
5 discovered I had to take off the gearbox cross member so….
6 fitting an exhaust took me about 4 weeks
 
I will take a picture of mine later if it helps?

as for bolts, nuts and washers. I buy a mixed metric pack from namrick - they do it by weight. Me and a couple of mates but a few KGs every couple of years and split them to share the cost.
I keep them in organisers, organised by type and size. Bit anal but tbh it saves time in the long run. For ‘specials’ I just order what I need from ‘Kayfast’

v8250 said:
They are difficult to fit but go in with a little patience & be sure to lube the threads too.

@JokerUK , fit as follows:

  1. fit downpipe to manifold using exhaust sealant and nip up exhaust clamp tight enough to just hold in place
  2. fit bracket and loosely tighten
  3. fit remainder of exhaust system
  4. fully tighten downpipe bracket and manifold clamp
  5. fully tighten remainder of exhaust system
note: the downpipe upper flare sometimes needs opening/fettling to ensure a proper fit to manifold
Click to expand...

I couldn’t get my bracket to line up with the upper clamp tightened, I had to support the exhaust from below, so the bracket then nip up the clamp
 
flat said:
I will take a picture of mine later if it helps?

as for bolts, nuts and washers. I buy a mixed metric pack from namrick - they do it by weight. Me and a couple of mates but a few KGs every couple of years and split them to share the cost.
I keep them in organisers, organised by type and size. Bit anal but tbh it saves time in the long run. For ‘specials’ I just order what I need from ‘Kayfast’



I couldn’t get my bracket to line up with the upper clamp tightened, I had to support the exhaust from below, so the bracket then nip up the clamp
Click to expand...


I just looked at Kayfast - that looks to be a good place to use

<I keep them in organisers, organised by type and size>. nothing anal about being organised!
 
Ok, I’ve spent some more time trying to work out the problem and, looking and the bolt hole nearer the front, I suspected that an engine mounting bracket to block bolt would fit, as I had one, I cut it down to size and fettled all the sharp bits off and can get it roughly in place and it appears it would fit however…..
The engine mount bracket is too close to the hole. - which reminds me somewhat belatedly… I used a disco block when I rebuilt the engine and apart from all the other bits that I had to change, I had assumed the base block would be the same- might I be wrong?

Anyway, I reckon if I remove the engine mount I can get the left exhaust support bracket bolt in and as long as I align the flats the engine mount will fit back (famous last words) it somehow doesn’t seem right though

steve
 
JokerUK said:
Ok, I’ve spent some more time trying to work out the problem and, looking and the bolt hole nearer the front, I suspected that an engine mounting bracket to block bolt would fit, as I had one, I cut it down to size and fettled all the sharp bits off and can get it roughly in place and it appears it would fit however…..
The engine mount bracket is too close to the hole. - which reminds me somewhat belatedly… I used a disco block when I rebuilt the engine and apart from all the other bits that I had to change, I had assumed the base block would be the same- might I be wrong?

Anyway, I reckon if I remove the engine mount I can get the left exhaust support bracket bolt in and as long as I align the flats the engine mount will fit back (famous last words) it somehow doesn’t seem right though

steve
Click to expand...

because it is so close a hex headed bolt is used for clearance iirc

I recall the same clearance issue.

blocks are identical it’s just the ancillaries that’s are different between disco/defender
 
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