rojbarker · Nov 9, 2009

My rear muffler fell off on Saturday and I noticed a massive hole in the intermediate pipe too. Instead of bodging it an welding it up, I found a new full system on fleabay for about £50.

LAND ROVER 200TDI DISCOVERY 1 EXHAUST SYSTEM '89-'94 on eBay (end time 13-Nov-09 13:21:32 GMT)

Has anyone fitted their own system like this? Any tips? Plus, will it need welding? As far as I can tell, it's all flanged so might get away with not welding

discool · Nov 9, 2009

Although my disco is petrol it only took an hour in total to replace the mid and rear box, as you say it's flanges. The hardest part is jacking up the rear and taking the near side wheel off and removing the old stuff mine was original so was one piece and had to be cut off, the exhaust hangers unbolt which makes removal of the rubbers easer when the hangers are on the ground, that's it job done. Get a spray can of waxoyl and do a bit of touch up while u r under the disco,

rojbarker · Nov 9, 2009

I had a bit of trouble getting the old one off (was only hanging on by the rubber hanger at one end) - was going to take the wheel off. Found I got enough space to pull it out by jacking up the body with the jack under the tow bar. I reckon when I fit the new one I'll do as you say and take the wheel off - no point messing around if I'm going to be under there a while!
Why do these things always happen at the start of winter?! (and 3 weeks before the MOT!)

discool · Nov 9, 2009

That's right always in the winter. U may know this, but when fitting the new rear part of the exhaust you approch the axel from the rear with the exhaust pipe upside down (ie. tail pipe facing upwards) and twist it as it goes over the axle. That's my top tip

aston108 · Nov 9, 2009

fitted one very similar to my 300tdi, didn't have to take any wheels of but did unbolt the exhaust hanger to sort out the rubbers, took me about an hr start to finish. I reversed onto some car ramps to gime me more room.

rojbarker · Nov 9, 2009

Cheers lads, I'm feeling a lot more confident about it now. Might post some while I do it in case it helps anyone else....

Bet it's ****ing down with rain when I go to fit it, in which case I might not bother trying to be helpful! haha

[JP] · Nov 9, 2009

what you goin to do with the old one? you wanna give it to me?

I need some pipe to fabricate a straight through exhaust on mine...

hey!
Just noticed you are in Andover! I live in newbury, but when i go out to the plains, my mates are all from Andover..

rojbarker · Nov 10, 2009

It's yours if you want it JP, I was just going to chuck it anyway. I'll PM you when it's off and see when your around my way next. I don't mind holding on to for a while.

[JP] · Nov 10, 2009

Ok, brilliant..
I'm always down in Andover anyway as my missus lives there..

let me know once its off...

cheers!
JP

uncle albert · Nov 10, 2009

check price at independents might get same with waranty ,and earsy to fit with ramps or similar,fit both loosly first ,position,tighten,job done!just watch bend over axle it runs very close and is prone to rattle if not spot on

rojbarker · Nov 11, 2009

The parts turned up yesterday - I only ordered it Sunday off ebay so pretty happy with that. It doesn't weigh a lot so not sure of the quality yet....who knows, could be made out of titanium (that's what I could tell people....!)
If it looks like I'm going to do a krap job, I may well take it in my mates garage to get it fitted.
Thanks for the tip about the axel - last thing I will want it readjusting it every weekend over winter!

string · Nov 13, 2009

I had the rear box fall off my 200TDI earlier in the year, bought a new 2 part system from my local Landrover shop. Getting the remains of the original off was simple, took a grinder to it. The problem with the new part was the weight so I went underneth with the centre section and my son fed in the rear section. Best to loosely fit the parts because the rear box has a tendancy to swing about and if your unlucky, like I was you will tighten it up and it will be hard up against the rear splash shield. The damn thing knocked like hell and I had to undo it all and re adjust.

If you exclude the re visit it took about an hour to fit.

rojbarker · Nov 14, 2009

Got the box sections of exhaust off in about 15 minutes in the piddling rain yesterday - I need a new front pipe too 'cos mines screwed! It's split from front to back the whole way down the weld seam. Had to bash the fecker to get it off the downpipe for about 30 minutes.
New front pipe arrived today so will try and fit it all together tomorrow - weather permitting!!

rojbarker · Nov 16, 2009

Pics of the removed exhaust - it's in a poor state.

Also the new part doesn't match the old one too well - look at the last pic and tell me what you think.

[JP] · Nov 16, 2009

that last pic is quite a difference hey!
My downpipe has a couple of holes right at the end (well, at least the ones I can see..), so I managed to get a new one off ebay for 15quid!
but havent fitted it yet, but it does look very similar to the new one you have there..

have you fitted it already? was it difficult to match, seeing its different from original?

rojbarker · Nov 16, 2009

I didn't get chance this weekend. The weather has been crap!
Might brave it one night this week or will have to wait till Friday.
It's about the right length but the new one is slightly shorter and the angles are all a bit wrong. I'll let you know how I get on.
Had it not been for that, it'd have been an hours work I reckon!

rojbarker · Nov 23, 2009

Well I fitted it - took 15 minutes to fit centre and rear section. 5 minutes to fit front pipe but it's really not right. Keeps dropping off cast pipe section at front - it's just a little too short. Ordered another part from the guy I got the rest of the parts from - they had a part from 1989-1993 and one for 1993-1994 - I am assuming (after checking the VIN references) I have been given the earlier one. Or that's what I'm hoping! haha

See below for reference if you ever need one any body!:

LAND ROVER 200TDI DISCOVERY 1 EXHAUST FRONT PIPE 89-93 on eBay (end time 22-Dec-09 20:13:43 GMT)

Mines LA068XXX so I have to use this one (despite the image looking the same...):

LAND ROVER 200TDI DISCOVERY 1 EXHAUST FRONT PIPE 93-94 on eBay (end time 22-Dec-09 20:16:18 GMT)

[JP] · Nov 23, 2009

Opps!!!
I just hope I have the right one...

seen your PM mate, I'll be down your way today, but will be late...
but I'll let you know next time I'm there, probably friday..

rojbarker · Nov 24, 2009

Friday's fine, I should be about. I also have a couple of side exit pipes from my brother's Ford Pop - they have cherry bomb centre mufflers and are prety rusty too but I thought you might be interested in the stainless steel tips and the 90 degree bends on them - we were going to skip these too so you're welcome to have a look and see if you want them.

rojbarker · Nov 26, 2009

Got some pics of the nearly finished system. The new front pipe arrived yesterday so will fit it tomorrow. Bit of a pain having this go on for a couple weeks but nearly done!

If anyone hasn't done one before, it's really easy.

To remove old system:

Drive on ramps or raise front of vehicle (if required - if you're slim enough you can do it on the ground probably!....)
Unhook rear rubber hanging mount
Remove clamp around rear section (usually 13mm nuts) to centre box
Remove rear section from centre box
Jack rear of vehicle up from the body for extra clearance. I used the tow bar and got about 2 or 3 inches of lift with the wheels still on the ground. Be careful if you're using axel stands at the front that they don't drop the car....
Pull and turn the rear section out from underneath as you go - You may find the pulling it forwards from under the car (as opposed to pulling it out from the rear of the vehicle) is easier. It's a bit tight over the axel but if you need a few more inches, just jack the rear up a bit more.
Once rear section is clear, you can drop the rear down again if required.
Undo the two bolts on the centre to front pipe section. 13mm again on mine
Pull centre clear of front pipe
Unhook the two rubber hangers on centre section
Remove centre section
Move underneath vehicle to front pipe
Reach up and remove the clamp around the manifold section at top of front pipe. I needed a 13mm socket, ratchet and long extension. You may also need a 13mm spanner if the clamp does not have a captive nut
Try and remove the front pipe from manifold section. Mind your eyes as loads of krap will probably fall out. If it's well stuck, try this:
Open bonnet and find the top of the front pipe on the manifold
With a tough flat blade screwdriver and hammer, try the get down the lip between the front pipe and the cast manifold.
CArefully hammer the driver down, forcing the swaged end of the pipe off the cast section. Move around the circumference as you go.
Try to lever the front pipe edges off a little as you got. It will eventually drop off.
Replacement is a reversal of removal (thank you Haynes!) I left the bolts loose till I got it all in place and nipped them up once I checked for clearance. You may want to use some firegum assemble paste on the flanges.
When putting rear section in, try to do it the same way you took it out.
Tighten nuts up good an tight.
Start up and check for leaks. Check for knocking or rubbing.
Should be job done.

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