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1G Reinstalling exhaust manifold & turbo, what anti-seize/sealant/RTV to use on which fasteners?

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XC92

5+ Year Contributor
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Jul 22, 2020
Queens, New York
I recently removed my '92 Talon's entire exhaust system to clean, derust, paint and overhaul it with new o-rings, gaskets and fasteners and am ready to put everything back on and just wanted to make sure what anti-seize/sealant/RTV to put on each fastener as a final sanity check.

1a - Exhaust manifold to head studs: Nickel anti-seize ok or use copper (I have both and read that the nickel could damage the O2 sensor) and on both threaded ends of studs?

1b - Center bottom manifold to head stud: Bore opens into oil gallery, is anti-seize enough or should I also apply something else and if so what and where?

1c - Center top manifold to head stud: I read that this may open into the coolant gallery, and if so how to treat that stud?

2 - Exhaust manifold to turbo bolts (replacing stud with bolt): Nickel or copper?

3 - Turbo to O2 housing bolts/stud (using all new ones): Nickel or copper?

4 - O2 housing to downpipe nuts: Nickel or copper?

5 - O2 sensor: Copper or nickel (new Denso came with copper)?

6 - Oil line banjo bolts: New crush washers enough, or add thread sealant and which?

7 - Coolant line banjo bolts: Ditto

And yes, I'm using the proper washers for all of these, crush, spring, flat, etc., and OEM gaskets and o-rings (4-ply on exhaust manifold).
 
Are you planning to use OEM fasteners or aftermarket? I'd stay away from stainless if aftermarket. I hear those seize really bad.
I like to use copper anti-seize on all exhaust bolts/studs/nuts.

1b: RTV (I use ultra grey, but any high temp RTV will work) on the head side of the stud. Anti-seize on the nut side.
1c: No oil or coolant passages here.
6, 7: Crush washers alone should be enough
 
Are you planning to use OEM fasteners or aftermarket? I'd stay away from stainless if aftermarket. I hear those seize really bad.
I like to use copper anti-seize on all exhaust bolts/studs/nuts.

1b: RTV (I use ultra grey, but any high temp RTV will work) on the head side of the stud. Anti-seize on the nut side.
1c: No oil or coolant passages here.
6, 7: Crush washers alone should be enough
Everything is OEM, studs, bolts, nuts, washers, gaskets, o-rings, etc.
 
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