Exhaust Leak from manifold to ext. WG

[rEclipserGST]

I searched. Nothing too current or definite about fixing the apparent exhaust leak on the manifold that meets the Tial external wastegate. I have this bolts as tight as they can got with limited amount of tools I have. It sucks because I can not get a socket around it because of the tight spot. RTV black silicone sealant, JB weld, or some kind of gunk to seal it? I need pro opinions about things that have been tried, tested, and true. My battery light and another red light under it are dim. Which makes me believe that there MAYBE excess heat hurting the alternator. But as you can see, my dump tube is slow and dumps almost directly onto my exhaust downpipe. I just need suggestions and want to make sure my alternator isn't being hurt. I just got this car out the shop and do not want it breaking down anytime soon.

Here is a link to my other picture BEFORE there was contact to my dump tube pipe. I notice a slight gap compared to before and after pictures. Any way to fix this?

http://www.dsmtuners.com/forums/newbie-forum/343253-external-wg-dumping-near-ofh.html

Also, what cutting tool or metal cutting disk should I use to cut the dump tube? I want to remove 1.5 - 2 inches from it to reduce any further damage. Thanks for looking guys.

 

[corsair231]

No comment on the dump location but as far as the bolts being tight you have some options. You can get a chasis bolt that has a smaller head to increase the clearance in the tight spots or you can get an allen head socket bolt that uses a hex wrench to tighten. (I know you can get the socket bolt at Lowe's.) Make sure you use anti-sieze on which ever you use. You may need to double your gasket or use some hi-temp rtv (red or copper). I would not use JB Weld.

 

[pboglio]

I use the high temp copper colored rtv but it still may be way too hot for the wastegate. I'd switch over to a fire ring gasket if you could. Try and get the surfaces machined or hand filed flat as that will seal it up. One possible reason your having sealing issues is that you have nearly 2 ft of pipe dangling off the wastegate. I would seriously consider some kind of mounting brace near the end of the pipe that will take the vibration and impact loads. I bet your sealing problems go away after that.

 

[rEclipserGST]

I use the high temp copper colored rtv but it still may be way too hot for the wastegate. I'd switch over to a fire ring gasket if you could. Try and get the surfaces machined or hand filed flat as that will seal it up. One possible reason your having sealing issues is that you have nearly 2 ft of pipe dangling off the wastegate. I would seriously consider some kind of mounting brace near the end of the pipe that will take the vibration and impact loads. I bet your sealing problems go away after that.

Great suggestions, the dump tube did make contact with something, I can see a dent in the front bottom part. I think that is why there is a slight gap now and exhaust leakage. But Cutting 1.5 to 2 inches off should definitely secure from any other contacts. Selling it with rtv and using allen wrench type bolts will hopefully help as well with some resurfacing Any other suggestions??

 

[EagleTSIawd]

have you taken out the bolts to inspect them?, they could have gotten bent and thus giving you a leak on top (that is where the leak is, right?). A some what similar problem happened to me on my downpipe, the two bolts that connect on the o2 housing some how got bent and a gap opened and burnt up the gasket. I got a new gasket and bolts and it sealed up just fine.

 

[pboglio]

Great suggestions, the dump tube did make contact with something, I can see a dent in the front bottom part. I think that is why there is a slight gap now and exhaust leakage. But Cutting 1.5 to 2 inches off should definitely secure from any other contacts. Selling it with rtv and using allen wrench type bolts will hopefully help as well with some resurfacing Any other suggestions??

What I'm saying is you need to clamp part of the dump pipe to something rigid that will keep the whole length of pipe from working the bolts loose on the wastegate. Those 2 bolts simply are not enough with that much weight hanging off. Same exact principal as the downpipe, without the downpipe brace those 2 bolts work loose and the gasket burns out. Anything else you do is temporary, my 3 cents anyways.

 

[My1GLaser]

Great suggestions, the dump tube did make contact with something, I can see a dent in the front bottom part. I think that is why there is a slight gap now and exhaust leakage. But Cutting 1.5 to 2 inches off should definitely secure from any other contacts. Selling it with rtv and using allen wrench type bolts will hopefully help as well with some resurfacing Any other suggestions??

Don't be surprised if Lowes doesn't have those exact bolts. Sometimes they don't carry all the metric equivalents of the SAE bolts they have. Go to Ace Hdwe and ask for socket cap screws. I believe they are 8x1.25mm.

I don't think RTV will last long. What you can try is a normal exhaust gasket that is made for flanged connections. Midas carries them, but not normally that small. I went to Adv Auto with my WG and they found some that matched up. I believe they are 1 1/2."

I don't think the thin metal one will seal anymore and the std exh gaskets are meatier. Unless you resurface the hell out of it which will take a LONG time by hand. You could always wait til Monday and take it to a machine shop to resurface it properly.

 

[pboglio]

I agree if your not skilled have them resurface it at a machine shop, but IMHO this is standard procedure number 1, then a decent gasket, bolts, and a restraining bracket. RTV will turn to a useless powder at these temps, I'd only use it on the low pressure side of the turbo where the exhaust temps are lower.

 

[rEclipserGST]

I cut the dump tube just now, i wish i would have done it earlier because it has perfect clearance and the exhaust will still be swept away from the air passing under the car. Checking the bolts to see if they are bent is a great idea, I'll do that asap. As far as bracing the dump pipe, where and how should I do that? The pipe is only about an inch wide and lightweight. But I'm down for whatever may fix it.