Exhaust manifold leak

[B-lackGSX99]

Hi there, i've got a leak in my exhaust manifold as indicated in the pictures below. I've tightened the turbo-exhaust manifold bolts (in particular the ones circled) to the high end of spec (47 ft-lbs). This helped a great deal, but there is still a mild amount of air leaking out. Wondering if there is any spray/paste I can apply to the leak area in order to fully seal it up. Suggestions / comments??

 

[elfroggo]

Replace the exhaust manifold/turbo gasket?

 

[B-lackGSX99]

Searched through the forums, read a bit about the variety of different turbo-exhaust manifold gaskets. I've taken a good look at stock ones, the stainless steel slowboyracing, RRE 7cm turbine housing gasket. and copper ones. I'm currently leaning the most towards the RRE gasket, read the most good things about it. However, wondering if anyone can give me any further feedback! Also, how can I be sure that the RRE gasket will fit my car? I'm assuming that they are all the same, regardless of whether or not the turbo compressor housing has been changed or anything like that...please correct me if I am wrong.

Also, I would like to pick up a new set of studs/bolts for the manifold, mine are currently pretty disgustingly rusty. In fact, I snapped off one of the bolts that holds the exhast manifold heat shield on...the one that goes at the bottom. Is it alright that I leave the rest of the bolt in there without the head on?? I can't get it out...thank you for your help!

 

[turbo addict]

Searched through the forums, read a bit about the variety of different turbo-exhaust manifold gaskets. I've taken a good look at stock ones, the stainless steel slowboyracing, RRE 7cm turbine housing gasket. and copper ones. I'm currently leaning the most towards the RRE gasket, read the most good things about it. However, wondering if anyone can give me any further feedback! Also, how can I be sure that the RRE gasket will fit my car? I'm assuming that they are all the same, regardless of whether or not the turbo compressor housing has been changed or anything like that...please correct me if I am wrong.

Also, I would like to pick up a new set of studs/bolts for the manifold, mine are currently pretty disgustingly rusty. In fact, I snapped off one of the bolts that holds the exhast manifold heat shield on...the one that goes at the bottom. Is it alright that I leave the rest of the bolt in there without the head on?? I can't get it out...thank you for your help!

From my experience the rre is the best, I have one on my car right now and it has never given me any problems in over 5 years. I have reused it several times and still works great, cannot say enough about rre gaskets.

Be careful when pulling the exhaust manifold studs out, spray them down with wd40 or pb blaster over 2-3 days once or twice a day and when pulling them out use either a stud extractor or a couple of new steel bolts to lock nut them, don't use the stock mitsu bolts to pull them out as they are too soft and can f-up the threads, the new steel ones won't give and crush together (as the stock ones can do) and the studs come out much easier.
I just did this this last week.

 

[romeen]

Even though I have an RRE stainless steel gasket I am a fan of the oem style gaskets. There have been some cases of the SS expanding to the point of breaking the turbo bolts, although turbo addict has clearly had good success with his. I'm not sure what the inlet diameter of the 20G turbine housing is, you might want to confirm by shooting RRE and email or do some searching before buying the gasket. If it has a 60mm (2.36") inlet (same as a 16G) then RRE has both the SS and the 2 layer oem style which will fit it.

As far as replacing the exhaust manifold studs once option it to use stainless ones. It just depends on how much you want to spend and whether you are after cosmetic value. Try here for an example:

http://www.ssstuds.com/

If you decide to get these make sure you get the 2G set that has seven 8mm studs and two 10mm studs which is what you need for a '99.

Regarding the one broken bolt for the heat shield, don't worry about it. As long as the others are ok and the heat shield is secure it won't make any difference.

 

[B-lackGSX99]

Okay, checked out ssstuds.com and will probably grab the stainless set with the copper bolts. I am assuming here that the copper is going to be advantageous in some way or other (more maliable? better ability to flex-unflex under heat?)...I have no desire to make my underhood area "pretty", so let me know if there are equally functional options that perhaps don't involve any unnecessary "pretty" parts.

As far as the replacement gasket goes, I am looking now the most closely at RRE's website, but can't figure out which gasket would suit my need to fill in the area shown in the picture above where the leak is coming from. I thought at first that I needed the 7cm turbine housing gasket because the shape (squarish) looks right, and it has four bolt holes at each corner...but the name of the gasket doesn't add up to me. Can anyone let me know which gasket I should be looking at?? http://www.roadraceengineering.com/flangesandgaskets.htm

 

[Rice Over Wheat]

7cm gasket is the one for manifold to turbine housing. I bought a thick steel one from Dejon. For the manifold to block I like the 4 layer copper gasket Dejon sells as well.

 

[B-lackGSX99]

Alright, i'll go ahead an pick up on of the 7cm turbine housing gaskets, and a new stainless steel stud set from ssstuds.com. If I use a stud extractor to undo the four bolts that hold the exhaust manifold to the turbine housing, will I be able to access / swap out the gasket, or will I need to remove a bunch of things first?? How can I find out exactly where the seven 8mm studds and two 10mm studs go?? Any recommendations on anything else that needs to be done in order to button everything up in the end and have hopefully no leaks?? Thank you for your help.

 

[turbo addict]

Okay, checked out ssstuds.com and will probably grab the stainless set with the copper bolts. I am assuming here that the copper is going to be advantageous in some way or other (more maliable? better ability to flex-unflex under heat?)...I have no desire to make my underhood area "pretty", so let me know if there are equally functional options that perhaps don't involve any unnecessary "pretty" parts.

As far as the replacement gasket goes, I am looking now the most closely at RRE's website, but can't figure out which gasket would suit my need to fill in the area shown in the picture above where the leak is coming from. I thought at first that I needed the 7cm turbine housing gasket because the shape (squarish) looks right, and it has four bolt holes at each corner...but the name of the gasket doesn't add up to me. Can anyone let me know which gasket I should be looking at?? http://www.roadraceengineering.com/flangesandgaskets.htm

This is what I have (http://www.roadraceengineering.com/eclturbos.htm)
4 Layer SS Exhaust Manifold Gasket $16

Combo Sale:
4 Layer Gasket and a 7cm SS turbine housing gasket $30
And the evo 3 turbine to O2 housing gasket.
I have reused them 3 or 4 times and for 2 different turbos and they are off now and will be reused again for my third turbo upgrade, still zero leaking problems and RRE has very good customer service, everyone makes mistakes but when RRE did on one of my orders they took care of it right away no questions or truobles of any kind.

 

[B-lackGSX99]

Okay, so I torqued all of the turbo-manifold bolts/studs and it really helped a lot. The turbo now spools up fine, but the car doesn't feel like it's getting turbo-pull/power until I hit about 10lbs of boost. Anyways, there is still an exhaust leak, but not from the area circled in the above picture...now it feels like it's still coming out of the place where the mani-turbo gasket should seal, but it's from the back area, underneath the 1 and 2 runners.

So, in order to replace this gasket (i'll also do the exhaust mani gasket and studs too while i'm in there), i've ordered the following:
1) stainless steel stud set from ssstuds.com. for the exhaust mani
2) 4-ply exhaust mani gasket
3) new turbo bolts (4, so that I can replace the stud), 8 convex washers.
4) turbo gasket from JNZ...I wanted a stainless steel one, but hope this does the trick.

Also, i've decided to grab a set of 4 NGK BRP6ES's for the hell of it.

I have a socket set that has both the 12 and 14mm pieces, as well as an adjustable torque wrench that tightens to all required spec values. Also, I have a closed wrench that I can use to get off the lower studs from the exhaust mani...hopefully.

Do you guys recommend that I pick up some high temp. rtv sealant to place on each side of the gaskets prior to instsall?? I am also considering going out and grabbing a set of vice grips, in case I need them for sticky stud removal.

Am I missing anything (parts/tools) that will be necessary to complete this job??

 

[ROOKIE1]

Pbblaster..

 

[B-lackGSX99]

I love the insanely quick responses on this forum, it's unbelievable.

Where can I can PB Blaster from?? I've read quite a bit about it throughout my searches on this topic, can't believe I forgot about it...does NAPA stock that stuff?? I'll pick some up and being spraying it a couple times a day prior to getting started.

 

[B-lackGSX99]

With the leaking exhaust, and the lower IC pipe that kept blowing off back in December (i've since had that fixed), my A/C fan has melted into wonderful looking globules of fun. In turn, I have unplugged it and removed the shroud from the backside of the radiator. I am wondering what will happen if I run my A/C now without that fan in place (it's getting pretty warm out these days)...will my condenser blow up?? Or will I just not be able to get as cold air as I used to??

I am thinking of getting a SPAL pull fan (I am fairly certain that a 12 inch fan is all that's going to fit in there with the stock radiator/passenger side fan next to it). I've read lots on the forums about it, but am hesitating because I don't know about the whole splicing it in thing. I may just try to find another used stock A/C fan and re-install...suggestions?? Thanks for your help!

 

[zippyshoe]

I love the insanely quick responses on this forum, it's unbelievable.

Where can I can PB Blaster from?? I've read quite a bit about it throughout my searches on this topic, can't believe I forgot about it...does NAPA stock that stuff?? I'll pick some up and being spraying it a couple times a day prior to getting started.

PB Blaster is readily available. You should be able to find it at your local hardware store.

 

[TSIMonsteR]

I know I am a little late, but I had the same problem and I bought the Copper Titan gasket from ffwdconnection.com along with an exhaust mani gasket. I don't think I'll ever have to replace either gasket again. They are great.

 

[B-lackGSX99]

Any recommendations as far as things you found really tricky?? I'll be giving it a shot in a week or so when the parts come in!

 

[zippyshoe]

Any recommendations as far as things you found really tricky?? I'll be giving it a shot in a week or so when the parts come in!

One item I can think of is to make sure you install the convex washers correctly. The second to last post of this thread shows the correct orientation of these washers: http://www.dsmtuners.com/forums/showthread.php?t=222822. Also, you mentioned that you had an issue with melting fans - one thing that can cause this problem (along with prematurely failing alternators) is if your exhaust heat shields are not installed. If this is the case, then you may want to look into installing these heat shields. Hope this helps!

 

[Cs4g63]

Did you try using the high temp copper spray on the exhaust gasket?

 

[TSIMonsteR]

make sure to use anti-seize on all the bolts and studs and try to keep the torque even between them. Like others have said, soak everything in PB Blaster, over night if you can. As long as you can get decent leverage, you should have much of a problem. Its an easy job.

 

[B-lackGSX99]

High temp copper spray?? Sounds good, is this something that I want to use prior to installing the new gaskets and studs/bolts, or something that I should use in conjunction?? From what I've read, the copper spray is to be used as a first step / method in sealing up leaks...and an RTV high temp sealant should be used in conjunction with the install of the new gaskets and such. I haven't read any comments confirming this, but please do let me know if i'm incorrect.

I will also make sure to pick up some anti-sieze and pb blaster!! Thank you for your help!

 

[underradar92]

Look for super high temp (2000*f) anti-sieze, the other stuff isn't always reliable.

Spray on copper works ok, or not. I use it, on the manifold to turbo gasket, but have never found any remains of it upon dis-assembly, so it may or not be doing anything.

No sealer is recommended on the head to manifold gaskets, it get so hot that it'll just burn away anyhoo.

While you have the manifold off check the flanges for straightness. Any warpage, especially on the turbo flange, and you will be doing this again, and again.

 

[B-lackGSX99]

For the reference of anyone that is searching for a fix to symptoms similar to what I had, here is the turbo-mani gasket that I pulled out of my car. The leak I felt was coming directly out of the area that has clearly burnt away. Easy enough to replace, now no leak! Thank you all for your help.