Has anyone had any success in repairing a split in the plastic inlet manifold / rocker cover assembly?

Apparently this is quite a common problem with these engines and my indie has said it will be thick end of a grand to replace it.

Any advice gratefully received.

Thanks
Andy

can it not be plastic welded pal ??

Mikeyp has recently had the same problem.
Has yours split / cracked in the same place?

http://www.fullfatrr.com/forum/topic44102....v8+cracked G reg 2.5VM Vogue Portofino red 1991- 1999
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https://www.fullfatrr.com/forum/topic56162...tty+affair

I believe Andy has the 3.6

Andy where has it split, I'm getting the occasional limp mode and I think I have a leak somewhere.

Sorry for the delay in getting back to you PaulB, very limited time to get on line at the moment. Also, I should have made clear I have the 3.6 as Paul correctly says.

The attached picture shows the right hand manifold assembly with the crack running parallel with the moulded joint between the rocker cover part and the manifold part.

I have attempted a temporary repair by using an aerosol parts cleaning solvent and a toothbrush to de gunk the general area then a medium grit pad taped to a screwdriver to rough up the area along the length of the split. I have then applied several layers of Sikaflex along the length of the split plus extra at the ends and sides to attempt to seal it.

Sikaflex is a marine adhesive product which remains flexible but is immensely strong. As an example, if trying to separate two fibreglass components bonded together with the stuff, you have to very careful not to damage the components as this stuff will pull the finished gel coat off.

It is clearly working so far, as I have racked up a few miles and so far no repetition of the problem. I'm firmly grasping the biggest piece of wood I can find as I type this

Paul, my initial thoughts based on info from the forum was a split hose in the induction but I went through all the obvious bits and couldn't see anything. I had noticed a sooty area on top of the engine slightly inboard of the manifold but was unaware of the issues with these manifolds. I took it to Steve Toyer in Penryn and one of his guys took all of 30 seconds to find the split manifold.

Family holiday next week to Wales so will plan to fit a new manifold in a couple of weeks. I've been quoted £380 by Carrs of Truro for the manifold assembly which includes the gasket. I'm just praying my bodge will last the week, otherwise I'll have Mrs C giving me grief every time I have to pull over and re start it

Cheers for now

Andy

Click image to enlarge

That's a great help Andy, thanks.
I'm currently on holiday in Perranporth and I'm getting the occasional limp mode either when towing or going up hill.
As you say I've also checked the hoses.
I will give the manifold a check over later.
This has been happening for over a year now!!!

Hi Paul

After I told him I'd checked all the hoses the mechanic at Steve Toyer got his torch and went straight to the two manifolds and spotted the crack in less than 30 seconds. He reckoned they would charge somewhere around £8-900 to replace the manifold as it looks like a complete pig of a job!

My symptoms were very similar. When going up hill, i.e. when the load on the engine increased and the turbos spooled up increasing boost pressure. I have developed a technique for reducing it by being very careful with the throttle in these conditions and that has helped a lot. Also, it would only happen after half an hour to an hour after thermal expansion has opened up the split.

I'll let you know how my temporary repair gets on next week with our trip to Wales.
Cheers
Andy

Thanks Andy

Did you have any fault codes read?

When it first started happening, I was in Hampshire for a few days and took it to Keith Gott and they did scan it. I'm afraid I didn't see what the code was but it was picking up a mismatch between the air flow sensors and the manifold pressure sensors indicating a leak in the induction system somewhere.

I hope you are enjoying our fine Cornish weather!

Best
Andy

Nice temporary fix. Well done. ______________________________
Vogue tdv8 08MY poverty pack - wow

The weather has been amazing Andy, especially today.

I can't find any visible cracks on the manifold.
I think I need to get it pressure tested when I get home.

Glad to hear you're enjoying the weather Paul. My guess is a smoke test would be more revealing as you would physically see the leak.

My repair seems to have worked OK so far, as we had a five hour trip yesterday, with two adults and an assortment of stroppy teenagers (X 3) and associated luggage, driving normally and not a single 'Engine System Fault' in sight

However, within minutes of arriving at our destination, the internal door release mechanism in the drivers door went pop and the handle just flaps around doing nothing. I now have to open the drivers window and lean out to open the door from the outside

Any info on this latest catastrophe would be much appreciated please but I'll make it the subject of a new thread.

Thanks
Andy

You could try and see if these guys can help you out!

http://www.belzona.com/en/index.aspx

I've never used anything on plastic before, but I've repaired aluminium carbs on one of my bikes and an engine block that had a hole in it. Worth a call maybe. Good luck. Current: TDV8 (3.6) RRS HSE



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Discovery 3 Commercial
TDV8(3.6) Vogue
TD6 Vogue
D2 V8 ES
D1 V8 ES
RR Vogue Classic

Thanks for that Stu.
We returned from Wales yesterday, clocking up another 350 miles on my repair and it is still holding up. I'm tempted to leave it for a while to see how long it lasts for, as this may prove to be a reasonable and practical repair, either temporary or not for these manifolds.

Mine has run for about 14 hours, covering about 700 miles so far with no repetition of the problem and I have been driving normally and with a fair load in the car.

I'll let you know as soon as it all starts to go wrong

Andy