Outer Limits 4x4 Board

I have tried everything, had the manifoldl machined, new gaskets, different engine....

Every blody time its ok for a couple of weeks then comes back again, as I said, I have had the head machined, the manifold machined, and have just recently installed a secondhand engine, bought a gasket for it and did it why is out, this one lasted about 50kms

Please help, is there something i should be doing when installing these

They are cheep to replace, but with all the work that goes with them i would prefer to just get it right

Not sure specifically for your car, but I used to have similar issues with another car - in the end, the only thing that fixed it was a liberal coating of that copper gasket spray.

Sealed everything up rock tight, and still havn't had any issues with it, probably coming up to 10 years now.

Are you using a torque wrench to set the studs and nuts tight? or using the good ol torque elbow?

no I havnt been using a torque wrench, didnt even think about it to be honest, i will also look into that spray

Thank you both for the replies

Definetly use a torque wrench, costs a bit (or is a pain in the ass on your own behalf) if you need to remove/replace the studs.

Look at it as cheap insurance

Don't know if it applies to your problem, but i had a similar problem on mine.
Besides using a thin layer of exhaust mounting compound on the gasket, i realized that if the turbo is mounted on the manifold before it goes into the car, the support running from the turbo exhaust outlet to the enginge block prevented me from tightening the manifold sufficiently to the cylinder head.
I loosened the three nuts holding this support to the turbo before tightening the manifold, and then retightened them after the manifold nuts were tightened. Been good for half a year now.

Thanks guys, will try those ideas, hope i dont snap any bolts, already had to remove a broken stud, pITA

did you machine the inlet manifold at the same time....inlet and exhaust have to be the same width or it won't tighten right.......

Yes you will have to take the turbo off especially if you machined the manifold cause it will hold the manifold away from the head...

My mechanic mate also said to use two gaskets if it continued on mine.

A few years back (maybe six), my car started leaking from the exhaust manifold - and here's what happened:

- Firstly it was removed, machined, then re-fitted. Started to leak again 3 months later.
- Secondly, it was removed, cleaned up, welded where a crack had appeared. Lasted 5 months before the crack reappeared.
- Thirdly, they replaced the whole turbo manifold for a brand new one. Have not had any problems since then.

Cheers - Coxy

I really don't know if it applies to the SD33, but I know for sure on other cars, the sheer weight of the turbo (and exhaust sometimes) will bend the manifold, especially when its hot.

Some people will make little brackets to bolt the turbo onto the block/head or somewhere else to help support the weight & take the strain off the manifold.

totto wrote:Don't know if it applies to your problem, but i had a similar problem on mine.
Besides using a thin layer of exhaust mounting compound on the gasket, i realized that if the turbo is mounted on the manifold before it goes into the car, the support running from the turbo exhaust outlet to the enginge block prevented me from tightening the manifold sufficiently to the cylinder head.
I loosened the three nuts holding this support to the turbo before tightening the manifold, and then retightened them after the manifold nuts were tightened. Been good for half a year now.

I had the same problem as this and had to grind away some material so it would pull up tight