TD42 exhaust manifold

[0-TJ-0]

Hi all,

I had a traul through the old "exhaust manifold" threads and can't find exactly what I'm looking for.

Since I swapped the turbo to a bigger unit I've developed a bit of a whistle when the exhaust is cold. I worked out there's a bit of a leak in the exhaust where the turbo mounts and assume this is my issue.

My question is;

Since I'm going to pull the whole lot off to fix it anyway is it worth swapping to a 1 piece exhaust manifold? Or just
Machine the old one? Pros and cons?

Also, if I just stick with the standard 2 piece is there going to be issues getting the two parts to seal once I pull them off and put them back on? I've never dickered with the 2 piece setups.

[0-TJ-0]

Bump.

Anyone? I'm mostly worried about the two parts sealing properly when i put it back together.

[AB]

You shouldn't need a one piece in my opinion mate.

have you tried taking it off again and inspecting and giving a good clean first?

I had a slight leak, very very minor after taking my turbo off 45 times when diagnosing issues. No whistle but slight soot coming out, after a few hundred km's the soot has now blocked it...lol

[0-TJ-0]

Alright. Might just order a new gasket and studs. Pull it off and try again before I have the whole manifold off.

Thanks mate.

[AB]

Alright. Might just order a new gasket and studs. Pull it off and try again before I have the whole manifold off.

Thanks mate.

I would absolutely do that as a starter mate.

Cheap first check.

Inspect, slowly clean, have a couple of beers type clean, inspect for any cuts on both flanges too and try again.

Even distributed tightening of bolts, etc.


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[mudski]

Make sure you use genuine gaskets. And torque them down evenly and you shouldn't see any issues.

[0-TJ-0]

So I got the manifold off the other day and had a good look. Hopefully just going to pull the studs out where the turbo mounts, give it a light sand/clean with a block and put it back together. Wrong.

78527

78528
The face is a corroded mess. The whole thing is going to need to come off to fix that.

Got it off and looks like the engine side will need a touch up too now I've disturbed it.

78529

Took it to a local place that specials in heads but they do manifold work as well. Cleaned it up pretty good while trying to take as little material as they could..
78530

78531

Now, they had to take it apart to do the turbo face as there's a protruding mount on the manifold that was going to interfere with thier mill. Looks like I need to give the join a bit of a clean up with a wire brush. Does anyone have any tips on putting it back together so it doesn't leak? I'm thinking I'll put a bit of that exhaust gasket goo in there.

78532

[0-TJ-0]

Didn't get many pictures today as I had a mate giving me a hand and didn't want to waste the opportunity!

Cleaned up the mating surface and put a couple of new studs in the block, replacing the ones that the nuts seized on and pulled the lot out. The remaining ones looked to be in surprisingly good nick so left them alone. New patrolapart locking nuts for the lot though. New Nissan steel gaskets all around so hopefully get a few years out of it now.

Cleaned the mating joint between the two pieces of the manifold with a wire brush on the drill. Nice tight fit. Couldn't get them together cold but heated the female part up with a torch and it slipped together nicely.. got a few nuts on quick and all bolted up nice.

78540

Also got a new engine mount in while I had all that off. Wasn't totally knackered but was starting to crack and easy to get to so she also got a freshen up.

78541

Bit more swearing and finally got it all back together tonight. No more whistle! Will drive it for a bit and pull the heat shield back off and see how it all looks/check for leaks.

Might actually be able to use it one day soon!