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Topic: 2.3 inlet manifold - good advice needed (Read 513 times) |
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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2.3 inlet manifold - good advice needed
« on: Feb 16th, 2007, 2:46am » |
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Just posted a bit in the news & problems concerning the hassle I've had tonight with that lump of plastic s**t 
Anyway, got a spare manifold in the post from Scorpius yesterday for the price of the postage (top man  ).......was said to be cracked.
The crack on it (on the body, next to ECT hole) is minute compared to the crack that I repaired on mine a few months ago, & seeing as it is off the car, then a good repair shouldn't be a problem as far as I can see ....
May give Devcon a ring in the morning, to see if I can get some of there stuff locally. I'm not using that quicksteel again........it may be water proof, but it definately ain't anti-freeze proof 
Anyway, as I've never taken off or fitted a 2.3 inlet manifold, then it would be nice to hear from someone that has.....as I can't find any procedure on the site.
Does it have a proper big gasket, or is it just the rubber port seals that seal it to the head ?
If it's just the rubber port seals, then will I definately need new ones ?.......
& what about the 'O' rings for the fuel rail/injectors....will the old ones suffice, or will they have to be new as well ?
Also the EGR pipe rubber sealing ring....does that need to be new as well?
& what about the IACV double rubber ring seal.....new ?
Oh ,& not forgetting the throttle body rubber sealing ring.....new as well ?
Can't think of anything else I may need at the moment, but I'm sure there is something I've missed
Also....what are the torque (Nm) settings for the manifold to head bolts ?
It would be good to have some quick advice...but please, the right advice only (no guessing  ), because recently this car (as much as I love it) is really starting to affect my ability to earn a living 
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TiberiuS
Senior Member
Ex. 1996 2.3 Ultima - RIP P789 KHJ
 
Posts: 2257
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Re: 2.3 inlet manifold
« Reply #1 on: Feb 16th, 2007, 3:25am » |
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Jonny, guessing I know (hit me ) but Matt replaced one with the manifold from a 2.0, it's metal and not plastic apparently; doesn't suffer this fault.
Might be worth a thought
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Bruce - '07 Jaguar XKR coupe, '95 Jaguar XJ Sport 4.0, '82 Ford Capri 2.0 Ghia, '15 Honda Civic (sloooooww..)
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scorpio_man
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Ford Kuga awd
Posts: 5654
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Re: 2.3 inlet manifold - good advice needed
« Reply #2 on: Feb 16th, 2007, 8:44am » |
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hi jc
torque settings
manifold removal
strange about the quicksteel. never had a problem with my repair (over a year, touch wood etc!). that being said, my manifold wasn't cracked. i had screwed the ect brass nut out of the manifold.
hth
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: 2.3 inlet manifold - good advice needed
« Reply #3 on: Feb 16th, 2007, 10:18am » |
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Cheers guys,.....If I can't get any Devcon, then I suppose I'll have to persevere with the quicksteel
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: 2.3 inlet manifold - good advice needed
« Reply #4 on: Feb 16th, 2007, 11:28am » |
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Can't get the Devcon locally....well not unless I wait a few days. But did manage to get some J-B Weld, so gonna give that a go
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davidberryman
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I'm a YaBB newbie!
Posts: 32
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Re: 2.3 inlet manifold - good advice needed
« Reply #5 on: Feb 16th, 2007, 3:47pm » |
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recently replaced my cracked manifold (having removed it the crack would be almost impossible to repair properly) got second hand from spikies scorpios via e-bay, as for removal, straight forward enough just take ya time, didn't replace seals only EGR gskt.
hardest bit is removal of lower three studs (star socket reqd), without removal of these you ain't gonna get manifold off, dont forget to remeber orientation of EGR pipe from rear of block with trans dipstick (if auto) i did and had to backpedal a bit.
Just a thought but if you've any reservations about your Fuel cut-off loom nows the ideal time to change it, i did as had been repaired poorly.
Good luck
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: 2.3 inlet manifold - good advice needed
« Reply #6 on: Feb 16th, 2007, 8:17pm » |
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Thanks for tips mate
P.S...how much did you pay Steve Saville for the manifold.
I see he's trying to get £155 for them now 
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davidberryman
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Re: 2.3 inlet manifold - good advice needed
« Reply #7 on: Feb 17th, 2007, 5:33pm » |
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asked for £95 + £20 post, accepted £100.00 delivered, guess he knows they're hard to find and taking advantage!
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: 2.3 inlet manifold - good advice needed
« Reply #8 on: Feb 18th, 2007, 1:06am » |
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Job almost done....just got to flush the system through & refill it....then, fingers crossed, I'm back on the road
For anyone that was thinking........
......."I bet when he gets the manifold off, he'll find that the head is cracked between the water port & number one"........
.....I was thinking that as well, but no crack....just residue from the old rubber gaskets & some carbon staining
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P.S....there were two cracks on the new manifold....a small one where the ECT housing starts (only about 5mm, & hadn't gone all the way through)....& a larger one on top of the T-stat housing (can't think how I didn't initially see it), which was an inch long & went all the way through.
Anyway....sealed both cracks outside & inside with a hot knife & applied 'J-B Weld' to inside & outside.
I said earlier in this post that I didn't think 'Quicksteel' was anti-freeze proof....it looks as though I was wrong, as the quicksteel that was applied to the crack on the inside of the old manifold was still holding strong.
On saying that though...the quicksteel that was holding the ECT brass nut in gave way for some reason
The J-B Weld that I've used this time does seem alot stronger than the Quicksteel (took 15 hours to cure) & seems to have a better bond to the plastic.
Although I didn't have to apply it to the brass nuts, as they were intact....I did anyway, just to make sure
So hopefully, the repair will be permanent & no more advice needed......cheers all
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Simmo
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I'm an OAP !
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Re: 2.3 inlet manifold - good advice needed
« Reply #9 on: Feb 18th, 2007, 5:54am » |
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Good luck JC.....I think you're due some!. Mike.
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Now I'm an OAP
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scorpio_man
Administrator
Ford Kuga awd
Posts: 5654
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Re: 2.3 inlet manifold - good advice needed
« Reply #10 on: Feb 18th, 2007, 1:07pm » |
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hi jc
what are you doing with you're old manifold. do you plan to fix that as a spare? how was the cracks compared to the 'new' one? same places?
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: 2.3 inlet manifold - good advice needed
« Reply #11 on: Feb 18th, 2007, 7:57pm » |
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The old manifold was cracked in a different place. It was cracked from the matrix outlet to the end of the ECT hole, so holding the ECT brass nut in was almost impossible as the housing would force apart.
Ran into another problem today though.
Noticed that the matrix pipe outlet seemed a bit loose, so I gave it a tug & guess what, yep, it came out ....
The rubber sealing ring had disintigrated. Managed to get the one out of my old manifold & the rubber ring was fine, so just hammered it home (lightly) & it seemed nice & tight.
But as a rule...if it's come out once, then it is bound to come out again.....so I slapped a load more J-B Weld around that as well  .......should have hardened by the morning.
I don't think I'll be repairing the old one again....I think it's gone past that point
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