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HOW TO FIX A TD5 WARPED EXHAUST

HOW TO FIX A TD5 WARPED EXHAUST

by Trevor Cuthbert, 14th July 2016

How to

The Td5’s exhaust manifold is prone to warping and breaking studs. It’s all repairable, and there’s a kit to beef-up the fixings. Trevor Cuthbert explains

Has the Td5 engine in your Discovery 2 or Defender developed a high-pitched whistle or squeal from the engine bay? If it has, the chances are that your exhaust manifold has become warped and will have broken a stud or two – or pulled the studs from the cylinder head. The squeal that one hears is the exhaust gases being expelled under high pressure through the tiny gap that has opened up between the manifold and the cylinder head. The temperatures generated within the Td5 exhaust manifold can be quite extreme. When the engine is driven very hard or if it’s highly tuned or perhaps doing a lot of heavy towing, the temperatures become so great that the tendency for the manifold to warp is stronger than the studs holding it in place. It is most common for a stud at the front or rear of the engine to break first. A tell-tale sign will be sooty deposits around the manifold and cylinder head. There might also be a drop in performance, lower power and reduced fuel economy.



> REMOVING THE MANIFOLD (SEE STEPS)
AS WITH virtually any job on a Land Rover, if a methodical approach is used, the removal of all the old parts should be a fairly straight forward task. There are ten nuts on the studs holding the manifold to the engine, and some of these are really quite inaccessible. But with patience, and perhaps making some stubby spanners by cutting them down to size (as shown later), the manifold will eventually come off.

>FITTING THE NEW MANIFOLD (SEE STEPS)
There is no need to buy a brand new exhaust manifold for your engine, when carrying out this repair. Your local Land Rover parts specialist will probably have in stock a second hand exhaust manifold which has been machined. They will require your old manifold on an exchange basis. If not, you can take the original warped manifold to a good engineering works where they will machine the mating surface of the manifold flat again. There is a theory that once a Td5 exhaust manifold has warped and been machined flat again, it will not warp further, but I can’t confirm this. 

TIME: 4 HOURS | COST: PARTS £168

TOOLS:
General workshop tools, drill, M10 tap, welder

COST:
Exchange exhaust manifold £99; uprated manifold stud kit £60; manifold gasket £9

CONTACT:
• BLRC www.blrcvehiclespecialist.co.uk Tel: 028 9751 1763 
• Alive Tuning www.alivetuning.com Tel: 01472 812900

1
STEP 1
STEP 1

REMOVING THE MANIFOLD: The acoustic cover has been removed from the top of the engine by removing the three bolts, as has the trim over the top of the radiator and fan.

2
STEP 2
STEP 2

The air intake hose to the turbo charger is also removed by loosening the jubilee clip and unclipping from the air cleaner at the opposite end.

3
STEP 3
STEP 3

The tell-tale sooty deposits on this engine are found at the rear, where one stud has been pulled out of the cylinder head, with the threads ripped out.

4
STEP 4
STEP 4

Remove the nuts holding the manifold in place, using a 13 mm socket wrench. Some are difficult to get at and require a small spanner.

5
STEP 5
STEP 5

With air conditioning, the drive belt is removed and the AC compressor unbolted and moved to one side. No need to break the refrigerant circuit.

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