Bongo Fury

Greetings,

I want to sort out an exhaust blow between the cast iron exhaust manifold (non turbo)
and out exhaust system (2 litre petrol 1999)

Can anyone provide a photo and a part number for the gasket to use?

I have experience of two types of gasket, a flat gasket with a fire ring (traditional)
and a light grey coloured crush ring (an anulus)

I think the latter ring is for use between the middle pipe and the rear exhaust system.

What is supposed to be in each place?

The fiche for this bit is Below:

To make it more complicated, we have a stainless steel system (incl. cat bypass)

Many thanks

Dr B

https://html2-f.scribdassets.com/5gms8k ... d89116.jpg

try this drawing, if you click on the number on the drawing itself it gives you the part number etc in the left margin.

http://lushprojects.com/bongopartsmk2/c ... mgno=.html

G60440305 40305 GASKET ???A NO.1
WL0140305 40305 GASKET ???A NO.2

I have the following observation(s):

The two halves of the manifold to system have a pair of lips which appear to mate up to form a seal of some degree, the flat gasket is therefore protected from the hot exhaust.

In removing the existing flat gasket, it was obvious there had been some blow-by evident by black carbon. Further examination confirmed the two halves of the joint were mis-aligned as a result of the less than conscientious manner in which the stainless steel cat bypass pipe was made by XXXXXX in XXXXXXXX. Basically the two faces being pulled together were not parallel.

A spare flat gasket was placed with the slightest hint of exhaust assembly paste (to take up any fine damage to the mounting faces by past screwdrivering), the clamping nuts and washers put in place and a trolley jack used to lift the bypass pipe up a wee bit so the two halves could clamp up square. Then the jack was removed and the gearbox mount to exhaust plate resecured.

Sure enough, this time, the seal is good.....

if the part mentioned had been made correctly things may have been better, the proper way to make bits is to have a lead in lip on the previous piece, this goes into the next piece usually by 5-10 mm, so working from front to back the 1st piece goes inside the next and so on, this lines things up correctly, strengthens the joint but also keeps the hot gasses away from the joint/gasket.

As I noted

Purple Pixie wrote:The two halves of the manifold to system have a pair of lips which appear to mate up to form a seal of some degree, the flat gasket is therefore protected from the hot exhaust.

.... I think the issue is down to a slight misalignment between the 2 mating plates

I have just swapped the exhaust back to the catalyst section between manifold and back boxes for the MOT

THis unfortunately involved welding on a replacement lambda sensor collar/ring as the threads in the old one finally bit the dust
https://www.flickr.com/photos/johnbulla ... ed-public/

Can someone describe the gaskets or crush rings that are used as standard at the start and end of this piece and maybe provide part numbers

I have a selection of traditional flat gaskets with integral fire rings however there appears to be a stand-alone crushable ring fitted between the manifold (2l petrol) and the cat section and a more complicated stand-alone crushable ring between the cat section and the back system

It would be good to be able to fit what is standard as at this moment in time I don't have a flat gasket at the front only a crushable fire ring

It looks like it is only a one-shot crushable ring at either end....