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Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

2000 Defender 130 Td5 HCPU Nato Green No Canopy

Exhaust manifold leak

Exhaust manifold leak has been my biggest headache since day one.

I tried Aftermarket, OEM exhaust manifold gaskets, and even took another step further and added wedged washers to stop the nuts from vibrating loose with 12.9 bolts for they were breaking at lower boost levels..

Well it got me again, i took my brick of a sports car down the highway at legal speed limit of 120kph, and i blew through my exhaust gasket. I was getting 23psi at full boost, but it started to drop steadily and held at 19psi.

We are lookin to do a custom "paper" exhaust manifold gasket. We use it on our Mack trucks, and well it holds the pressure better than our engines oil...

I am running everything under the moon and back for this lil gal, modded airbox, with 102 inlet hose, all silicone hoses, SS modular exhaust manifold, Alive hybrid turbo, (gonna sell this lil badboy) Alive ultimate intercooler, egr delete, water injection, ported intake, and head, 2.5" transition to 3" downpipe, followed by a 70mm straight through catback.

There shouldnt be any restriction nor blockages in the exhaust nor the intake, and i get to boost quick enough.

i feel if i want to keep up with the flow the way i want to i may have to upgrade to a ford powerstroke 6.4 with ZF s750 gearbox...The only thing holdin me back is the stand alone Ecu and throttle control, dimensions are very similar...

19th Sep 2018 7:32am

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2945

Well, it sounds like you are running the engine beyond it’s BHP design parameters and this will expose weaknesses, which is what is happening here.

The standard exhaust down pipe has a flexible joint to reduce stress on the manifold joint, do you have a flexible joint on your system?

19th Sep 2018 11:52am

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2192

Surely if youre loosing boost its a boost leak opposed to an exhaust manifold leak, which could lead to slower spool but should adjust the PSI.

Could be loosing pressure on the inlet side. Instagram @defender_ventures
Empire Tuning - Agent

19th Sep 2018 12:10pm

isacs

Member Since: 28 Aug 2015
Location: Leamington spa
Posts: 404

Just drop the monster power stroke in!!

19th Sep 2018 12:37pm

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

lightning wrote:
Well, it sounds like you are running the engine beyond it’s BHP design parameters and this will expose weaknesses, which is what is happening here.

The standard exhaust down pipe has a flexible joint to reduce stress on the manifold joint, do you have a flexible joint on your system?

I have two, one one vertical and one horizontal.

Once i install the VNT turbo from TD5inside i will just have one on the horizontal right after the elbow on the bottom.

The power stroke wont work, but a duramax will, and same Zf gearbox...Just need to find the illusive ZF-6 for chervy, or talk with rakeway and see what the max torque their t-56 magnum can handle and be done with it...

19th Sep 2018 12:56pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

Hi Naf. Is your manifold slightly warped by chance?

Are you running a 2.5" exhaust throughout? I have heard that fitting a 3" downpipe that reduces to the 2.5" can help with the this problem. Bear in mind this is what I have been told and have not tried.

20th Sep 2018 8:48am

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

I have a 2.5" inlet to my exhaust, but its only 15cm long, it then opens to 3" and goes for about 2mtr, then i transition to a 2.75" for the rest of my exhaust.

On the VNT turbo i ordered it with a 3" outlet where i will merge to the rest of my system and have a 3" downpipe then transition to a 2.75 open system.

My manfold did warp twice, which i corrected.

20th Sep 2018 9:23am

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

Heck.. Sounds like you have that sorted then...

What has made you decide to swap from the hybrid to the VNT turbo if you don';t mind me asking?

20th Sep 2018 9:44am

gazman

Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

Your manifold is it tubular or std? I've heard a lot about aftermarket headers warping worse than the std ones.

I've been told the best option is a std warped one with the webbing removed and then skimmed flat again. Then run the upgraded Merc studs.

You can loose turbo pressure due to a manifold leak 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r

20th Sep 2018 4:07pm

derbywill

Member Since: 25 Mar 2010
Location: Derbyshire
Posts: 560

Alisport make an upgraded manifold looks better flowing aswell to help spool times, and has thicker flanges etc.

Cheers

Will 2005 90 XS
1954 86'' Series 1 tilt
1968 88” 2A 200tdi
2002 110 Hardtop

20th Sep 2018 7:48pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2945

Is it viable to weld up the manifold/down pipe joint?

21st Sep 2018 5:14pm

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