Exhuast Manifold Blown

[Simon R]

Hi all

97 XJ TD 2.5

Last week I had some small problems, this week it’s bigger. Looks like I've blown an exhaust manifold gasket, or worse a cracked manifold - lots of black soot all around the manifold area, out onto the hoses and up in between the rocker boxes. Using lots of fuel and causing a fair bit of smog as well!

Has anybody replaced the manifold, how hard is it and were the cheapest place to get parts - Jeep want $750 for a manifold 3 to 6 weeks delivery! Gasket is $70 & 5days delivery! Not only do Jeep rip us off with price, but they don't even stock the ** parts.

Anyhow, no good complaining still have to do it. Can anybody recommend a jeep recycler in the Perth area (or anywhere in Australia)? Any body know of an aftermarket gasket supplier?

[Stevo11]

I got my one piece metal gasket from here :

http://ccgi.vmspecialists.plus.com/r...5484d7fd80ca5c

Give him a ring, v.nice guy, he'll sort you out.

Steve

[The Smiths]

I've just changed my manifold and turbo gaskets today - took 11 hours.

I doubt it is the manifold - that is a big lump of cast steel and no stress points to go at.

I live in the UK, 20 miles from VM specialist.

I bought new manifold gaskets from the local motor factors - for a 2.4L range rover (could have been a rover 825 or other car that used VM engine - they are all the same). They only cost £1.70 each (£6.70 for steel ones from jeep in the UK).

I have done a few manifolds/ turbo's and my top tip is to remove the 4 top studs from the air inlet manifold then it will unhook and give good access to the exhaust manifold. Install the air inlet with the row of top studs missing as well.

Also use a banana shaped (hard to reach spanner) for the nut behind the exhasust port .

It really is worthwhile removing the top studs on the air inlet.

Also while it is all stripped out service the starter motot - only 15 minutes to remove it with nothing in the way

[dxj]

Hi,

Very unlikely exhaust manifold. Very likely blown or leaking EGR or EGR pipe/gasket.

Many people disconnect/remove the EGR before it breaks and damages the engine. On the 97..99 models (with VM 425CX1 engine) you get slight improvements in performance. Little performance change on late model 99..01 with VM 425 CX2).

If you still think it is the manifold, could be the expansion sleeve near no 1 cylinder.

[Simon R]

Thanks all. Still unsure where the leak is, but sounds like it's unlikley to be the the exhaust mainfold, but could be a gasket or the EGR unit or hose, I will only know when stripped down, but think I will blank of the EGR unit and hose (so that it doesn't operate at all).
I will post the outcomes to this thread when completed, for future referance.

[hemijeepy]

I reckon its a good time to tell the Mrs you need that massive t04 ball bearing turbo and stainless exhast system....... For "fuel ecconomy"

[murray]

hemi yuo better read the posts coz its a deisel
if he is having bag pipes fitted i will have them as well