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Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

Fitting new exhaust... Right pain

OK, so I will update my other thread about getting to this point... as it's been fun.

However I now have a new exhaust and have tried to fit the downpipe 3 times last night and just cannot get it to seat correctly.

Can I use any sealant or will this just blow out? I even used a jack to try to hold the down pipe in place. Just wasn't having it.

Any recommendations. The picture shows it lose, however you can see the pipe to manifold its not straight... it's not quite as offset as I can pick it up to get straighter but cannot get a good seal. Drove me mad last night trying

Click image to enlarge

6th Sep 2018 9:23am

LandRoverAnorak

Member Since: 17 Jul 2011
Location: Surrey
Posts: 11324

I'd be sending that back

Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia

6th Sep 2018 10:13am

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

^ I can get it much better than the picture shows, thats with the bolt lose.

If I hold it straighter and tighten it then It's much better but still not flush. Should it be flush? ie touching each other tight

6th Sep 2018 11:16am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17450

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Yes, it should be flush and should butt straight on to the manifold.

It's either completely the wrong shape, or else you are running it under the gearbox crossmember instead of above it.

6th Sep 2018 11:37am

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

Does this look correct how its routed?

I'm sure I copied the old one but maybe not?

Click image to enlarge

I will try an enlist a friend to help me twist it while I tighten it up

7th Sep 2018 8:56am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17450

That does not look right to me, it is much too near the ground, it should not be that low under the crossmember. If I remember correctly it should pass under the crossmember much nearer to the chassis, so that the exhaust pipe is not really any lower than the lower face of the crossmember.

7th Sep 2018 9:55am

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20453

It doesn't look right to re either, I'd try it the other way around possibly.

As Blackwolf mentioned, it looks to be sitting too low to me as well. No Guts, No Glory.
🇬🇧🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁳󠁣󠁴󠁿🇮🇪🇺🇸⛽️🛢️⚙️🧰💪

7th Sep 2018 10:24am

camelman

Member Since: 27 Feb 2013
Location: Peak District
Posts: 3373

That's way too far across under the cross member, heres a pic I've just taken of mine...

Click image to enlarge

7th Sep 2018 10:53am

camelman

Member Since: 27 Feb 2013
Location: Peak District
Posts: 3373

And the next section along.....

Click image to enlarge

7th Sep 2018 11:03am

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

Thanks people

I will have another look over the weekend.

Any more pictures of how it routes the better as I've printed them out to look at mine.

7th Sep 2018 2:37pm

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

All I had it routed wrong !!! 🙄

Next issue should his front connection be but up to each other as I can get it right (the picture is lose) but it's not bang up tight there is still a gap?

Click image to enlarge

Thanks

7th Sep 2018 4:21pm

rustandoil

Member Since: 08 Sep 2012
Location: Cotswolds
Posts: 745

2005 Defender 110 Td5 XS DCPU Bonatti Grey

That's how it should be.... A gap between the flange and the manifold 👍🏻..... Don't tighten it up until you have the whole system on the vehicle.

7th Sep 2018 4:34pm

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

Is the Gap normal? as it will not go tight and flush even now. Its still as above just tighter and a bit closer.

The big 'washer' on the exhaust side does not clamp up to the bottom of the manifold flush?

I don't want to start doing the rest if this isn't right?

7th Sep 2018 6:57pm

rustandoil

Member Since: 08 Sep 2012
Location: Cotswolds
Posts: 745

Yes, the "gap" is correct, the "big washer" you describe is clamping the fitting on the end of the downpipe into the manifold 👍🏻

8th Sep 2018 6:28am

Stacey007

Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3758

Fitted

Thanks for help, Yes I had it routed incorrectly so the first picture now is much tighter even than in that picture and more sealant for good measure.

Click image to enlarge

13th Sep 2018 10:48am

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