keep blowing exhaust manifold gaskets - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• keep blowing exhaust manifold gaskets by 1slowvw on 11 Mar, 2009 09:41
• Hey guys I just pulled my car out of storage the other day to do a clutch job (installed an ACT 6 puck race disc, and 16v preasure plate) and I'm noticing a few problems that should be addressed. First off I found that I'm leaking exhaust at the manifold again, I say again because this is not the first time and I replaced the gaskets mid way through last summer, I'm just wondering if anyone else is having trouble with these under high boost/temperature situations. I'm running an AZZ with the usual ticks, 1.6pin, increased fuel, k-24, FMIC running at about 20psi. Am i just not tourqing down the manifold hard enough? I know I need to pull it all apart to replace the gaskets and install my log manifold that is being built, I'm just wondering if I'm the only one with this problem?
  
  Thanks
  
  1SlowVW
• #1 by saurkraut on 11 Mar, 2009 09:54
• Nope, fairly common.  The manifold is warped.  I've had good results having the manifold re-ground across the port faces by the same folks that I have re-grind my heads.
• #2 by 1slowvw on 11 Mar, 2009 11:03
• I thought about getting it resurfaced but wasn't sure. Guess that's the route I will have to go.
  
  1SlowVW
• #3 by 1slowvw on 11 Mar, 2009 11:08
• Thanks here is a pic for kicks and gigles.
  
• #4 by smutts on 11 Mar, 2009 12:35
• Good old P-slots!
• #5 by myke_w on 11 Mar, 2009 12:35
• also - the regular paper gaskets are pretty crappy and often blow out regardless of manifold integrity.
  
  The next time you put it back together, be sure to use good ones that are impregnated metal mesh
  
  see pic
  
  
• #6 by 1slowvw on 11 Mar, 2009 13:03
• I have always used the metal gaskets wouldn't really trust the fiber ones.
  
  1SlowVW
• #7 by dieseltech on 12 Mar, 2009 06:59
• Quote from: "1slowvw"

  I have always used the metal gaskets wouldn't really trust the fiber ones.
  
  1SlowVW

  
  
  
  
  where would one get the metal ones?
  thanks
• #8 by 1slowvw on 12 Mar, 2009 07:26
• Don't quote me on this but I believe the 1.9TD's had them not sure where you could source them If you are in the US its quite possible that the early TDI's had the same ones. I'm sure someone here will chime in. I have always gotten them from my local VW shop, who gets them through a company called auto-camping.
  
  1SlowVW
• #9 by myke_w on 12 Mar, 2009 07:47
• I hate to beat this topic to death - considering your problem is likely warpage.
  
  But I want make sure I understand what you mean by metal...
  
  Is it all metal? or two layers of metal with paper pressed between.
  
  Ex.
  
  
  
  This gasket is not what I consider an ALL metal gasket.
  If you peel back the layers you find a paper material inside those
  
  I think these are more susceptible to blow outs than the fiber impregnated steel mesh, which is very tough and thick, they are absolutely hands down the toughest gaskets I've found.
• #10 by 1slowvw on 12 Mar, 2009 11:55
• Beat away, I have been using the all metal gaskets, as pictured.
  
  1SlowVW
• #11 by Smokey Eddy on 12 Mar, 2009 14:28
• You know, i remember taking OFF those metal fibre gaskets myke is mentioning and i don't think they had EVER been off before and they appeared to have no leaks... they would have been 18 years old.
  
  I replaced them with all metal ones. yes, all metal, no film in the middle. But i would trust the metal fibre over them any day. The fibre ones just make sense. I also emery clothed and wet dry'd my sufaces. no harm in lapping mating surfaces if you have something flat to do it with.