caldina gtt manifold warping problem

[gttNICK]

thanks for explaining everything.
The noises returned after perhaps 2-3 months of the original work

[Mr Revhead]

yep that sounds like a typical planed manifold im afraid.

[gttNICK]

so no reason to suspect dodgy helicoils?

[Mr Revhead]

its common for manifolds that have been planed to start leaking within 3-6 months.

[evil_si]

there is a lot of weight on the studs that are there, unfortunatly the one piece turbo exhuast housing / manifold doesnt help things

does the manifold have a slit between ports 2 and 3? if not and there are bolt holes either side cut a thin 2mm slit right through

make sure all the exhaust mounting points are intact on the entire exhuast, and the bracing from turbo to block is in place,
could be a good idea to put an extra couple in ??

im wondering if the extra bolt hole in the head could be utilised, maybe a piece welded to manifold to use it and replaned or possibly some type of wedge,

[evil_si]

gttnick, i see in your signature you have a turbo back exhaust,

were is the first support bracket? or mounting point,

particually on these cars and ones with cheap stainless manifolds, there should be one right up the front, within 4-6" of turbo then one under the engine before the flexi.

do you have a decent exhaust flexi?

a little bit of unsupported weight on the actual exhaust system acts as a lever and creates a lot more weight at the turbo end of it

[Mr Revhead]

im wondering if the extra bolt hole in the head could be utilised, maybe a piece welded to manifold to use it and replaned or possibly some type of wedge,

i think it was fivebob a while ago who suggested using that hole for a clamp. and im pretty sure its been done.

[evil_si]

sweet, if it hasnt been done might be worth getting some pics together and making a tech post on it.

[WCKWGN]

my after market headers just need a tidy around a weld, it hasnt lifted from the head.

pretty rank from toyota it is a design flaw and they are now not standing by there enginering. No matter when it was or wasnt made

to make it one piece with no flange to turbo was stupid. to say it is the end user who contributes to its demise is crap, moving parts like steel wheel or ceramic in the turbo should not be covered as they can be abused through not servicing oils or runnning high unsafe boost ... but some thing that is a manufacturing casting problem and that was fixed on the facelift caldinas, proving there was a fault with what they had done . i think toyota should come to the party of those with pre facelifts and see them right. It isnt fit for the purpose that it was manufactured....being subjected to high heat for prolong useage.


To have the individual shell out money to fix a toyota problem I think is rank

When mine warped it snapped a stud of the manifold , ping up and ripped the protective stuff under the bonnet pinged back onto the plastic cap on the alternator and shattered it..... hmmmm end user fault ??

Mine was planned back by Pitstop and put back on and had no other issues with it and motored on it for another year no probs. I had only 85,000kms. Imported it with 75,000kms.

Mitsi had a problem with there brakes 2 years ago and they recalled the VR4 Galants and Legnums from memory no matter how they got here Liceneced or privately imported they carried out the work needed to be done, so wether it comes off a signiture range Toyota dealership with a stacked price or not shouldnt matter at all as to if they stand by there worksmanship.

To get headers , turbo , fuel regulator, wastegate, ecu - install and dynod tuned, while you are there a FMIC + piping. it is a expensive way to repair some other monkeys mistake.

If it was only as easy as a after marker $600 headers that flanged onto the factory turbo and not have to look at ecus etc etc

my 2c

[Caldina3SGTE]

just wondering can u just cut the turbo off the manifold and get a new flanged welded on the turbo and then get a new manifold made up to suit?? is that possible?

[mr_monkey]

just wondering can u just cut the turbo off the manifold and get a new flanged welded on the turbo and then get a new manifold made up to suit?? is that possible?

Anything is possible if you have money.

[gleem]

hmmm if yours goes you may as well get a aftermarket turbo and manifold as its around $1600 for a new turbo from mr revhead, you could get a t3/t4 custom manifold and wastegate easily for that much, sure its best to get a ecu and tune it and all but you dont have too.

[lucasthefallen]

just last year toyota recalled old hilux surfs to replace steering relay rods......

[Zak]

The do quite a few recalls, mostly steering though.

At the moment, we are doing all the steering column's on all sorts of things, head light switchs on camrys, axles and all sorts.

No chance of them doing the caldinas though, too much labour and parts to do it properly. They are over 7 years old now so they are getting on a bit too.

[strx7]

a warped manifold or a snapped stud isn't a safety issues, its not going to kill anyone as a direct result, the steering related things they recall can do.

[gttNICK]

It is in the shop getting fixed as of today(hopefully for the last time). Manifold and turbo came off and helicoils were fine, had damaged the first stud again. Manifold is being flattened, stud replaced and a bracket made up. All turbo and exhaust brackets were fine and in place. Will try and get a pic of the bracket and post up.

[gttNICK]

Car is back and the manifold is silent (for the time being). It had shredded another stud (not the one that was helicoiled last time) and bowed again. The damaged stud was replaced and helicoiled and the manifold flattened. He made a bracket up which he said effectively adds a stud where the one is missing. Have to wait and see I suppose...

Hats off to Magoo Muffler in Dunedin for honouring the guarantee on their workmanship, the only bit I was charged for was the bracket.
And sorry I can't get a pic up, you can't see anything now its assembled again.

[Santa'sBoostinSleigh]

mines done over 160,000kms and is still fine *touch wood*

[Mr Revhead]

now that you said that it'll let go this weekend!

[Santa'sBoostinSleigh]

can you touch my wood too, just for luck....
i mean you are the one that weaseled your way into my cabin!

car has to pass a wof first, the exhaust is leaking like a b!tch at the back - time for gasket goo me thinks. its freaken pissing down with rain too
VTNZ are blind and passed it 6 months ago, but its got a bit worse and knowing my luck they'll ping me on it, just cause i dont have time to fix it