300tdi new exhaust gasket not aligning

AJofShabby

Member

Posts

78

Location

UK

• Jun 22, 2020

• #1

Afternoon all.

I am trying to replace a blowing exh gasket. New one ordered from Bearmach. When I tried to instal this PM the exh manifold studs are poorly aligned against the head. three of the top studs are a tight squeeze, the fourth (end) stud (and I have tried from both ends) will not align. See photo. The gasket wasn't a great alignment, either.

Oddly enough when I removed the old gasket the two main long inlet mani bolts we missing as were two exh studs, so I imagine this was a known problem when the engine was installed 5+ yrs ago.

Has anyone any ideas? Thanks

 

Attachments

• 
  IMG_7618.jpeg

  339 KB · Views: 193

Flossie

Well-Known Member

Posts

11,071

Location

Shropshire

• Jun 22, 2020

• #2

Head has been helicoiled? (Badly?)
Does the gasket line up with the manifold holes ok?
If it does it must be a poor repair to the head threads.

 

AJofShabby

Member

Posts

78

Location

UK

• Jun 22, 2020

• #3

It may be that the bullhorns are not tightly fitted. Also I think I need to refit the studs before trying to fit the exh mani. Is there a way to tighten up the bullhorns or is it just brute force?

 

Goc3k

Well-Known Member

Posts

300

Location

Hampshire

• Jul 20, 2020

• #4

You will have to torch the horns to get them to crack off, then it's brute force and ignorance to move them.

Plenty of old exhaust manifolds on ebay for cheap if you get desperate

 

freelance

Well-Known Member

Posts

8,725

Location

essex and beyond

• Jul 21, 2020

• #5

Manifold distortion

 

AJofShabby

Member

Posts

78

Location

UK

• Jul 29, 2020

• #6

Hi all. So the end result was that the horns had twisted and were reset easily but the missing studs were missing for a reason. They have been rethread. So all now sorted. Thanks all.