Birty Dastards Jeep Club
Tech Forum => Workshop => Topic started by: Brynjaminjones on January 26, 2014, 08:44:26 PM
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I'm not a happy chappy today. :011:
I've spent the best part of two days fitting my new exhaust manifold, only to find that I'd not seated the intake properly and so was greeted with an engine that sounded like it was ready to rev up to about 3,000,000rpm the moment I started it.
What myself and my mechanic realised upon closer inspection was that the flanges on the exhaust manifold (where the bolts hold them) are thicker than those on the intake manifold, meaning that surely it's impossible for the intake manifold to be held on properly??
I'll attach a couple of pictures - although not very clear they should still show you what I mean.
Is this normal, or do I need to get a new manifold??
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Incorrect part? so will they take returns or is it from the US? in which case i suggest you need to find a friendly engineer who will mill the manifold down to the right thickness for you :icon_rolleyes:
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grinder time! just take some meat of the ears that have the shared bolt on them
WTF were you doing, 2 days!
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'Tis from the US unfortunately. It looks to be the right part - it has the right number and fits perfectly in every other respect. Rockauto used to sell them but has now stopped; I'm wondering if this is why?
Anyway, I think I'm going to just buy a different one, as I don't know where I could get it milled, and if I leave it be I may be able to pursue as it came from Amazon.
P.S. I'm fairly new to this whole "using a spanner" thing, so took my time, faffed about a bit, got stuck on some parts, and generally made it take longer than it should have done! :lol_hitting:
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your uni got a engineering department ??
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your uni got a engineering department ??
It does indeed, and I'm even let loose in there sometimes! I need the XJ back ASAP though, and I don't think I'd be able to get anything done in there quickly. Maybe once I've got a new one on I could fix the other one and keep it or sell it on!
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put the old one back on for the mo ?
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Honestly, I'm lazy, and I just want this done and out of the way! :icon_redface:
I've just ordered a manifold on eBay the same as Maf (Green Jeep) recommended to me ages ago (and I should have gone for all along!), so hopefully I should be able to get that fitted next weekend!
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ok mate
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I appreciate the help though 8-)
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My Pacesetter headers came with stepped washer things for that problem cos the same problem occurred but it was the other way round with the intake being thicker.
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Really?? Might it be possible to get a photo of one, or are they all too hidden?
EDIT: Nevermind the photo, I've found what some look like now. They seem like the perfect solution, but I haven't a clue where to find them!
In case anyone's unsure what I'm looking for, scroll down to the last post on this page: http://blog.hemmings.com/index.php/2007/04/page/4/
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If you're handy with a grinder, you could make these yourself.
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:iagree:
and these
http://www.ebay.co.uk/itm/Stainless-M8-Extra-Thick-Spacer-Washers-Choose-Your-Quantity-/370956028554?pt=UK_DIY_Material_Nails_Fixing_MJ&var=&hash=item565eb3ca8a
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I've never actually used a grinder before, so wouldn't really know what I was doing!
One more concern I have - is it likely that I may have cracked my intake manifold by putting it on wonky and tightening it up??
Sent from my Sony Xperia using Tapatalk
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I think it'll be fine. Mine did the same thing when I fitted the headers and got a couple of the special washers the wrong way round (they spin around a bit when fiddling under the intake to fit them)
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That's good to hear!
It makes me feel much better to hear that you've done similar - it was really making me doubt whether I should be doing stuff like this myself instead of taking it to a garage!
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keep at the spannering made.
having a go is the best way to learn
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you have to learn to think outside the box,
get washers cut to suit the gap then bolt into place using spring washers with the split side over the spacers. if you broke the original manifold what would you have done?
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:iagree:..improvise!
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stepped washers deffo the way to go. used to use them all the time on old minis with odd manifolds way back in the day
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If I can find some then I'll use them - due to time I can't really make them myself. Do you have any idea where to get them from??
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stepped washers would normally be bespoke to the application, its a case of finding something and making/adapting them
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if you want to modify your manifold give me a shout and i'll try and fit some time in
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Cheers Dave - I really appreciate it, but I really do need to try to get the XJ back on the road next weekend as I need it the following week if possible.
Unless I come up with an idea that could do the same job as a stepped washer before then, I'm just going to put the new eBay manifold on.
I may well be interested in fixing the one that doesn't fit ready for another time though, so might take you up on your offer! :001:
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Dont step the washers they are that shape for a reason and dont leave them on the wonk either.
Put some packers under the washers so they sit flat, tack weld them to the washer and then torque the bolts per spec. Try to get the same clamping area on both manifolds so the pressure is evenly distributed and Bob's your uncle. Simples!
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I believe Bryn, looking at the above posts you have been shown the reason Birtys has the reputation it has, simply the best.
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Yup, I don't like to admit it but they are a good bunch! :icon_winkle:
My new manifold has arrived (from eBay) and it looks to be of excellent quality. I know it won't have the performance benefits as the other one, but I just can't wait to get my Jeep back - after just a week my friends are already telling me to shut up about how much I miss her! :003:
Hopefully I'll be fitting it tomorrow and Sunday, and hopefully without any problems - I should also be a fair bit quicker this time! :icon_super:
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I believe Bryn, looking at the above posts you have been shown the reason Birtys has the reputation it has, simply the best.
Its why i fit in so well :003:
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I believe Bryn, looking at the above posts you have been shown the reason Birtys has the reputation it has, simply the best.
Its why i fit in so well :003:
:iagree:
your the care project :hysterical:
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I believe Bryn, looking at the above posts you have been shown the reason Birtys has the reputation it has, simply the best.
Its why i fit in so well :003:
http://m.youtube.com/watch?v=Z9t_KDGqOmE
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:hysterical: :hysterical: :hysterical:
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That's good to hear!
It makes me feel much better to hear that you've done similar - it was really making me doubt whether I should be doing stuff like this myself instead of taking it to a garage!
Noooooo Don't go thinking like that... My spannering is all self taught.... Sometimes I wished that someone would do the job for me whilst lying in the snow with a torch on my gob but there is little that I wouldn't tackle now even though I can now afford main dealer prices... Just before christmas I removed the front end off the van and fitted a new alternator, aircon compressor,starter motor and gates couplings for the price of the parts and an afternoon...about £700 to me.... I shudder to think how much a garage would charge me for the same work....Stick at it and learn
Even my Jeep, Boris was bought with a cracked head and incorrectly fitted lift kit and no LPG but he was cheap but now he is a good and reliable motor
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I believe Bryn, looking at the above posts you have been shown the reason Birtys has the reputation it has, simply the best.
Its why i fit in so well :003:
There are exceptions to everything :003:
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That's good to hear!
It makes me feel much better to hear that you've done similar - it was really making me doubt whether I should be doing stuff like this myself instead of taking it to a garage!
Noooooo Don't go thinking like that... My spannering is all self taught.... Sometimes I wished that someone would do the job for me whilst lying in the snow with a torch on my gob but there is little that I wouldn't tackle now even though I can now afford main dealer prices... Just before christmas I removed the front end off the van and fitted a new alternator, aircon compressor,starter motor and gates couplings for the price of the parts and an afternoon...about £700 to me.... I shudder to think how much a garage would charge me for the same work....Stick at it and learn
Even my Jeep, Boris was bought with a cracked head and incorrectly fitted lift kit and no LPG but he was cheap but now he is a good and reliable motor
:iagree:
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I know it won't have the performance benefits as the other one, but I just can't wait to get my Jeep back
it would be hard to tell the difference between the two, if one quotes 20hp and the other 10hp above stock those figures are normally massaged claims and you would be hard to tell the difference on the road. i would have thought where max torque will be would be of more interest. if one sits it between 2 and 3k would be better than one having it 3 to 4k
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I've got my Jeepy back! It took me 3 1/2 hours from start to finish with no assistance at all, and now she's purring again!
Does that qualify me to leave the WTFIAS club??
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Taken it for a good test drive now, and it's driving beautifully.
It's been over a year since I first noticed the cracked manifold, so it seems quicker now. It keeps its speed a lot more easily, and hills don't feel like a struggle anymore!
I'm also enjoying how easily I can spin the inside rear tire pulling out of junctions (not that I'd do that deliberately :icon_winkle: )
:icon_super: :icon_super:
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I've got my Jeepy back! It took me 3 1/2 hours from start to finish with no assistance at all, and now she's purring again!
Does that qualify me to leave the WTFIAS club??
Sent from my Sony Xperia using Tapatalk
Top stuff!......I don't know what the WTFIAS club is but it sounds pretty disagreeable.... unless they serve cheap drinks at the bar.
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You're not leaving the club, you are thrown out by an unforgivable breach of rule No1 - shame on you :eusa_naughty:
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Uh oh, did I talk about the WTFIAS Club??
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:hysterical: :hysterical: