replacing 3sgte *EXAUST* manifold gasket, any tips or traps?

[steve74]

Hi, i have a leak on the far left of my EXHAUST manifold (caldina gt-t) and have been told it just requires a new gasket. im keen to fit it myself. are there any traps? i build motorcycle engines so im pretty mechanically minded. however i have heard horror stories about broken studs and helicoils. what is the best sealant to be used?

cheers, steve

[fivebob]

The biggest problem is access, it's pretty tight in there. IIRC there are three studs and the rest are bolts and the brake lines are fairly close so you may not be able to lift the manifold off the studs with the engine in place.

The stock gasket requires no sealant.

I'd also be a bit concerned as to why it's leaking in the first place, broken stud/bolt or warped manifold possibly, can't see how you'd make the call that it only requires a gasket if it's not been disassembled and checked.

These pics may be of some help as they show the location of the bolts and the length of the studs.

[steve74]

sorry fivebob, i meant the exhaust, dont know what the hell i was thinking. and after that indepth responce i kind of feel bad!!!

sorry for that. but at least i know about the inlet now too!! lol

[fivebob]

No problem

Well that's a bit easier then, but I'd still be concerned about why it's leaking. Being a steel gasket they don't tend to blow unless something else is wrong, earlier 3S-GTEs had a bad habit of warping the exhaust manifold and breaking studs and I seem to recall Mr Revhead indicating that the Caldina may have the same problem

[Akane]

early 7 stud heads are crap and tend to warp the exhaust manifold.

If yours is leaking, check for tolorances and get it machined if needed.
New studs and bolts are recommended
the Gasket costs $170ish or something.

Torque to spec, good luck.

[steve74]

oh poo!! i thought you might say that the studs are prone to giving trouble.
mine is a 98, so i guess its not such an early one. i downloaded a bgb manual for a 91 MR2 which gave me the tollerances for a warped manifold so i assume they are similar. the engine looks well looked after and corrosion free so with a can of crc at my side i will keep my fingers crossed.

cheers guys and thanks for the advise

[steve74]

Finally pulled the beast apart to find that the bottom far left hand manifold stud had shared off compleately. aparently this is a common thing with hilux manifolds, but the local toyota dealer said they havnt heard it happen in a late model 3sgte. a drill bit and an ezyout sorted it. new studs all round and will check the manifold for warping.