I did some online searching and found out that pretty much all the 4cyl diesels from Rover use the same manifold gasket. Since I had a spare from my 2.25 diesel I went out today to put it on.
Much to my surprise I found my brake reservior leaking.$%^&* It never ends???? It's brand new!!!! So I emailed where I bought it in the UK, we'll see what happens.
I took off the intake and exhaust manifolds but kept the turbo in place. The nuts and threads look really rusty on it, so I didn't want to bust anything. It looks like someone's been there before as the rear bottom stud was replaced by a piece of cut off allthread. I didn't have a stud for it either so I put a bolt in.
Here is a pic of the old gasket, interestingly where the soot is you can see right thru the gasket in little holes.
You can see in the photos that #1 and #4 were both leaking putting soot all over the intake manifold. I cleaned up the intake manifold, removing all the soot and corrosion. I wire brushed the head clean and prepped it for the new gasket.
So since I have the same fiber gasket I thought I'd try something different to make it last. I checked my antisieze and it is rated to 1600F. So I put a light smear on both sides before installation. I also put antisieze on the stud ends.
Then the intake manifold was put on. It has to go on first because there are 2 hidden bolts holding it to the head.
Then my attention was turned to the exhaust manifold. Close inspection revealed that there was rust/exhaust gas pitting on the mating surface of the manifold tubes. These I cleaned up with my palm sander and 80 grit sandpaper. Then it could go back on.
By now the 1 hour job had gotten on to 2 and a half hours. I kept having to take stuff off and make things loose to get the manifods off. Hoses, oil pipes, exhaust down pipe. The exhaust down pipe had to be disconnected from the engine clamp, loosened at the first joint then pushed down out of the way. Plus it was getting hot!
I removed my sweatshirt, my teeshirt was drenched with sweat already and soon the sun would hit where I was toiling..........
As fast as I could I started to put on the exhaust manifold, it was almost impossible to get the oil return line hooked back up. I finally had to remove it from the bottom pipe and put it on the top pipe so it would go on. The nuts behind the turbo have to be fitted next because you can't get to them when all is flush againt the head. But it is always the last nut/bolt that gives ya the most problem.
There is a center nut between the 2 manifolds that you can't see or feel. I tried several ways to get &*$# nut and washer on. Finally I got the washer on with a small pickup magnet. I thought I then had the nut on with a deep socket and an extension. When I went to put the rachet on I heard the nut fall off. I looked for 10 minutes couldn't find it.............and of course didn't have another, oh, they are M8x1.25 by the way.
Now the sun is on me, I'm frelling filthy and sweating profusely my back is starting to tighten up and hurt again. So I just put all the tools away and close up shop. Went inside and cleaned myself up and had some lunch. Rested my back for a bit, changed clothes and went into town for some nuts.
By the time I returned it was still too hot and my back needed resting so I just relaxed inside. (did laundry actually)
Around 7pm I went back out and finished the job, the nut went right on??? I thrashed around in the dirt again working the down pipe back on and tightening bits up meanwhile the brake fluid continued to drip in my face. I don't have a photo of the finished job, I'll try to remember tomorrow. But I did run it and it was much quieter.
So here is the photo from this morning of the completed job. You'll notice I still need to figure out the air filter.
And some good news! I recieved an email this morning LRSeries is going to replace the defective brake master cylinder. Bully for them to stand behind what they sell!
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