Exhaust manifold not seating properly...

[90CherryTSI]

I have the feed line from the filter housing but I'm wanting to do something about the drain line. Even though it has a little flex in it I think it's keeping the turbo about 1/4 of an inch to high so it's forcing the exhaust manifold not to seat against the gasket. Has anyone modified this, maybe by cutting the middle section and clamping on some fuel hose or something? Has anyone modified their drain line like this for some type of custom routing or anything? I have the clamps and the hose but was wondering about any reason it wouldn't work....I can't see why it wouldn't. Right now if I unbolt my turbo/manifold the n the DP and drain line are the only things holding the turbo up. I don't think with a 2g mani that it'd crack or anything but I know the turbo does rest on that drain line a little for some support. Would it work? I don't want to spend $80 for the aftermarket line probably made with fuel hose and the same stuff I'd make mine out of just to have to get another when I get my new turbo in 6 months.

Thanks tuners!

 

[DSM90AWD]

I have the feed line from the filter housing but I'm wanting to do something about the drain line. Even though it has a little flex in it I think it's keeping the turbo about 1/4 of an inch to high so it's forcing the exhaust manifold not to seat against the gasket.

If all of your exhaust manifold bolts are torked down correctly, there is no way the OEM oil drain line could be causing the issue you think it is.

If you have a leak at the gasket, likely the gasket is blown or the manifold flange is warped. My original 1G manifold warped on me so I had it machined.

 

[90CherryTSI]

with the way it's bolted on now if I look at the flex section on the drain line it's smashed down a little and kinked about 5 degrees to the left. It comes up then zags a little then goes up again. Something isn't on straight but doesn't make sense is that the DP mated right up to the 02 housing and the wastegate arm also mated up right the gate. I remember before the drain line used to sit just right and not smash at all.

A little background -

I had an exhaust leak and it started melting the lower timing cover. I had replaced the exh mani gasket 4 months ago so I yanked it apart and it had been leaking again. When I bolt just the mani on w/o the turbo I can tell it's 100% sealed. Now when I bolt the turbo onto that it's pulling the mani at an angle but the ONLY thing holding the turbo to the car at this point is the drain line and like I noted above, it's kinked a little.

Hope this helps clear up my reasoning a little.

 

[DSM90AWD]

The exhaust manifold is connected to the head by 9 8mm studs/nuts torked to 20ft/lbs.
You could stand on the manifold (assuming you do not weigh > 300lbs) and it would not separate from the head, so the chance of a 30# turbo (even with oil return misalignment)causing separation is nil.

FYI.. 100% of the 1G oil pans I've seen are dented due to someone (whom didn't know better) jacked it up from there without using a block of wood (or other) to distribute load.

If you look at the point where the oil drain line enters the pan and where the dent is.. I think you'll find a relationship. It's normal and the oil return has a flex section to account for this

 

[90CherryTSI]

but I guess the true test is to take off the oil return line and see what happens. I was only basing this on the fact that the line was the only thing holding on the turbo and the manifold fit differently with it connected like that.

Thanks for the input, I'll try a couple things and possibly if need be have the flange resurfaced.

 

[DSM90AWD]

FYI.. the coolant feed line also "supports" the turbo so it doesn't go thru the radiator (with the turbo bolts/DP removed)

Definitely buy a decent Exh Manifold gasket (the metal mulit layers are best and re-usable), as more material to allow for little imperfections in the mating surfaces.

 

[Frank333]

I did cut the turbo oil return line and built up the middle with fuel line, just like you wanted to do. I wrapped the downpipe with header wrap to keep the heat away from it. I've been to 4 track days at VIR and never got that line warm from the exhaust! It works great!

 

[big_d]

...you realize this thread is 5 years old.