Found the budgie hidding in my engine....

[Paul1566]

Found the budgie hiding in the engine bay.....
Bit of a crap design me thinks...after buying another maniflod that was flat and fitting with cheap (compared to toyota) manifold gasket i had a budgie in the bay and here's why.......



If you look just left of port 3 you can see a faint round mark just before the flat shiny bit gets recessed bake and looks rough and lumpy.
Thats the impression left by the gasket copper rivet.



If you look between ports 3&4 you can see same impression.

Here's the gasket with copper rivet



Now the problem, the compressed gasket measures 0.55mm the rivit measures 1.95mm.....
Can you see where i am going....?????
No mater how tight the manifold studs are if the rivet does not sit in the rough recessed area there is no way you can compress the rivet down and make a good seal.......

here you can see between the gasket plates the blow out residue.....



so me thinks thats why she made the chirrping buzzing noise as the gasket vibrated when the gasses passed through them....

Gunna make sure that don't happen again.....

Paul1566

[TonyN]

I never use the new exhaust gaskets in the head kits, always reuse the Toy one, even used its far better.

[Paul1566]

Have a new manifold and gasket on order from toyota...
£110 for shiny flat as kiera knightly manifold....
£43 yes £43 for the gasket......

Gunna measure twice and fit once this time....

paul1566

[Paul1566]

Well yesterday picked up me shiny new manifold and gasket and took today off and went about helicoiling the stripped out head and then proceded to torque up the manifold when yep you guessed it another one stripped...$%^£^%£
So off came the manifold again and helicoil another one, thought about doing all of them then stopped thinking......
Only problem with the first helicoil was getting in there so had to pop round to hire centre and get right angle headed electric drill that cost me £15 to drill one hole......
She's all torqued up nice and running sweet.....all i need now is some snow to go play in......
Oh just a note to anyone changing the manifold gasket, get a toyota one its worth the money, the cheap one i brought was just 2 pieces of thin metal with a fat copper rivet that doesn't compress down.
The Toyota gasket is 8 pieces of thin metal with rivets sooooo tight they don't protrude at all.....
Obviously 8 pieces can take up slight warpage in your manifold as well....

Here's to doing some real surfing after all the work i have done...

Paul1566