I have an exhaust leak on the 240D. It's coming from the joint between the exhaust manifold and the first section of pipe in the exhaust system. I think there's a gasket that goes in that connection, but I haven't been able to find a part number for it. Any ideas? Yes I've checked the "Buy Parts" section here, and yes I used the "search" function but didn't find what I needed there either.

In other news, I also have a cracked exhaust manifold. I slathered some JB Weld on the crack and let it sit for two days before I started it. Surprisingly, it's holding up so far.

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Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

Did you take a look at the EPC? If my memory serves me correctly, there is no gasket there, metal or rubber. The pipes are held together tightly by the two metal rings on each side that are bolted together, and that creates the seal. The exact geometry of the fitting where the two pipes meet varies depending upon model year.

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Corey

'83 240D, 190kmi

I started reading the tutorial for the epc. I may subscribe in a day or two. How well does it work on SLOW internet connections?

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

Corey is correct - no flange gasket. The end of the pipe is convex and fits into the cancave end of the manifold. I would guess your manifold is still leaking and not the flange.

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Don't Chrome them; polish them

The EPC is a java app so it will load a few megabytes of data, I can't remember exactly how much. Once it's loaded and running, I don't think it will be too bad but to be honest I haven't tried it on a really slow connection.

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Corey

'83 240D, 190kmi

It's the flange. The manifold leak was between the #3 and #4 cylinders. I checked by starting the engine and putting my hand over the area. The manifold isn't leaking anymore, but the flange is blowing a pretty good stream of exhaust. Is there a fairly easy and inexpensive way to get that joint to seal again?

I think I'll hold off on the EPC subscription until I go home. I'm working in another city for a while and the internet access I have here isn't very fast (understatement).

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

The question is why it's leaking now. My #1 bet is corrosion in the area around the joint. There could be a hole at the joint. Or weakening of the metal, which could cause the seal to be lost if the joint was at all manipulated. The only way to know for sure is to take it apart and look.

Good luck.

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Corey

'83 240D, 190kmi

Understood. Where I'm currently staying wrenching is technically against the rules but small amounts are tolerated. I can use the hobby shop on the other end of the island, but I'd have to drive about three miles over there and then wait for it to cool off before I can start working on it. I'll figure something out.

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

I finally took it apart and looked. I didn't find excessive corrosion on the exhaust pipe, any holes, or anything missing. I did notice that the pipe is held rather firmly by the hanger at the back of the transmission and tends not to be centered in the manifold when the clamping ring is removed. I put the ring back on an tightened it down. I still have the leak. Should I loosen up the hanger at the transmission, get the pipe well aligned to the manifold and tightened down before re-tightening the hanger? Any other ideas?

In other news, I noticed lack of vacuum after I did the exploratory on the exhaust system. I'm thinking it's just a leak in a line somewhere.

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

That's what I would do. Working on that connection in the past, I could see how you might not get a good seal if you don't tighten it down with all other tension off the pipe. That might mean disconnecting the rest of the exhaust system to get the weight off the end of the pipe, too.

The only time I've fiddled with this connection is when I was replacing the pipe connected to the manifold due to corrosion more distally. In that case, I removed the rest of the exhaust system, connected the new pipe to the manifold securely, and then tightened the hanger at the transmission and put the rest of the exhaust system back on. But that's because I was replacing the pipe.

You might have displaced one of the vacuum connections to the EGR, not sure with your model year you might not have EGR to begin with. In any case, look for vacuum hard lines that have become disconnected, it happens easily.

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Corey

'83 240D, 190kmi

The exhaust leak is on hold for the moment. I've confirmed a vacuum pump failure. The diaphragm is busted. In addition to no vacuum, I've also got oil going through the hole in the diaphragm, through the tube into the air cleaner, and finally through the air cleaner drain holes onto the ground. I'm getting a junkyard vacuum pump this weekend. After that maybe I can fix my exhaust leak.

Edit: 1000th post! Whoot!

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

I found two diaphragm pumps in the junkyard, but both were too stuck to get off the donor cars. I settled for a piston pump instead. The install went pretty well until I tried to tighten the power steering pump back up. The belt made contact with the vacuum pump. I tried rotating the vacuum pump and messing with the power steering pump's position, but neither got rid of the contact issue. I removed the belt and am now driving around without power steering until the replacement diaphragm I ordered shows up.

I now have power brakes, shutoff using the key, and no oil leak.

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.

I replaced the exhaust manifold with a good one from a junkyard. No more cracked manifold and the flange under the hood is almost leak free. I can't believe how much quieter the car is now. And for some odd reason it feels like it has more power.

In addition, I ordered a vacuum pump gasket from Phil and put it in a while ago. Currently no vacuum troubles either.

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.