About the missing gasket for SF turbo kits....

[aerospike2002]

OK, is the missing gasket between where the manifold and turbocharger bolt together?

And if so, to those of you who have the SF kits WITHOUT having fixed that. Does it cause you to sometimes actually hear exhaust leaking out - like rushing air? And when that happens, the turbocharger struggles to spool up. Kind of "raspy and puffy" sound since it is not getting the full exhaust flow into it that it should be?

And did any of you have any problems fixing it with Liquid Copper Gasket? Because that is what I have been recommended to fix it with. Or, actually, any of those "gasket maker" products - they actually have those two words in their names.

By the way, I am assuming that the gasket did not come with the kit because, currently, it is difficult if not impossible to find a gasket that fits the inlet of a Garrett T3/TO4B. Correct?

Why SF did not tell anyone that it came without a gasket is beyond me though....

Anyway, thanks for the answers.

[Alfy1]

I was also wondering how one would go about finding out if they needed that gasket or not. I dont hear any noise or any raspiness. Do you know where I can order a gasket for a super 60?

I had a bad experience with liquid gasket maker. I put some between the block and the manifold and it boiled out of the manifold and went into my turbo. It was high temp copper too gasket maker too. I dont know, good luck with your install.

[mrtomcat]

good question. Mine is just "band-aid'ed" right now, I have not gotten an answer on a fix/solution as of yet either.

[aerospike2002]

It's already installed...and Alfy, did you let it dry overnight? Because if it was still wet when you put it back together, I would expect any sort of substance to "boil out."

For a T3 Super 60, look for a Saab gasket that will fit.

Guys, please tell me if that is the only place where it could be leaking? Because I feel it could be two places...between where the manifold and turbo inlet meet, and between where the turbo outlet and downpipe bolt together. Maybe also where the downpipe bolts to the midpipe.

I have no idea.....where was it leaking at for you guys? And what did it sound like / how did it affect boost?

[Masayver]

I'm not sure where my leak is, but all I know is that it smells like gas or exhaust when I'm driving and my windows or moon roof is open. I've checked for gas leaks in the engine bay and do no see any. I know that my exhaust manifold was not bolted on correctly for a long time (only held by one bolt) until I had SF fix that. It is now held on by two bolts but I have not inspected if there is still some sort of gap. I know that before, when there was only one bolt holding things together, my car was loud and raspy, but boost didn't seem to be effected at low or high boost. Since SF realigned my manifold/dp, my car sounds stock (maybe a bit louder) but definitely not like before, but the gas smell is still there. My boost has never fluctuated, according to my boost gauge.

[exotic performance]

i had a guy here make me one out of titainum.

[mrtomcat]

the other leak is the exhaust manifold, I got a new donut exhaust gasket and got it put back together. No leak for about a day then it started again.
I don't think the exhaust manifold is angled correctly and so the exhaust moves off a bit.
Maybe some special screws are needed to hold it in place better or some type of sealant tape that goes around it...no idea but the fumes are defintely back in town.

[aerospike2002]

READ THIS GUYS....WHAT DO YOU THINK IS WRONG WITH MY SETUP?

Masayver....I have the same problem...it's because having the windows or moonroof open creates a crossdraft and pulls the exhaust straight through the car.

It's weird though....I have to deal with it by never having my windows open and by always having my A/C control to the "outside vent" when I'm freeway driving and having it to the "inside circulate" when at low speeds. That's the only way I can't smell it - it is really a pain though, having to switch from internal to external vent all the time (when I enter town from the freeway and start driving slow, etc.)

I think the simple truth of the matter is, no matter how an exhaust manifold is designed, there should be a gasket in there. Why SF did not tell us that there was no gasket, I really cannot believe.

Now here's the problem with my car....I have this funky sound to the engine...it's like as follows:

1) When throttle applied or at WOT, you can hear air rushing out from somewhere and the turbo is really struggling to spool up...it's like "chug, chug, chug" or maybe better said, "pant, pant, pant" because it sounds like it's trying to breathe. Because this is happening with conjuction of an "air leak" sound, I can only assume that exhaust is leaking out between the manifold and turbocharger connection and not entering the snail at full presssure, so it can't spool up very well.

2) This is what I really hate - as of about 2 weeks ago, whenever I let off the throttle or press the clutch in, the engine has this really loud kind of raspy sound as it drops in RPM's....like, it actually gets louder the closer it comes to 800-1000 rpm's (where my car idles). The weird thing is that I really do not think that the sound is engine related - I can differentiate between the engine operating noise (like it's normal idling sound) and this new sound. My engine sounds healthy, but the sounds seems to be coming from right in front of me when I am in the car. Like right by the firewall....so I'm assuming that it has something to do with the exhaust setup and missing gaskets.

I kind of remember when I put on an axle-back exhaust on my vehicle once, and forgot to put the gasket between the axle connection and flange of the exhaust. It made a similar sound to this. I could hear air rushing out under throttle, and then when I backed off throttle or depressed the clutch, it would make a raspy noise....not as loud though since it's farther away from the engine.

[mrtomcat]

the smell comes from the exhaust leaking from where it's connected to the manifold. You need a new donut gasket.
I have the same problem. But as I said earlier the problem came back about a day or so later (after I went to the track).
That's why I think that some work needs to be done at the down pipe it's not aligned good enough to stay sealed.

I had that ai rushing noise as well until I got the manifold put back on (after the screws feel off and it almost fell off). That sound is now gone. You might want to take a look at it from underneath your car

I have the raspy sound around 2000 rpm. I was told that it's normal but I could swear that this was not there until a few weeks ago. I'm actually glad to know that someone else has the same issue makes me feel less insane.

[Alfy1]

Originally posted by mrtomcat
the other leak is the exhaust manifold, I got a new donut exhaust gasket and got it put back together. No leak for about a day then it started again.
I don't think the exhaust manifold is angled correctly and so the exhaust moves off a bit.
Maybe some special screws are needed to hold it in place better or some type of sealant tape that goes around it...no idea but the fumes are defintely back in town.

You think that If a flex peice was installed the alignment would be fixed?

[mrtomcat]

yep

the same would solve my problem with the intake pipe, now one just needs to find one that can withstand the heat and of course fits :)

[mrtomcat]

forgot to add: the other part that causes smell is that little breather, so getting rid of that would be worth while investigating as well, I guess putting it back into circulation like they do in stock turbos for example.

[aerospike2002]

^^

Yeah, that stupid breather...I hate it...I can see little puffs of exhaust or something coming out from under my hood which is expelled from that breather. Every time I pop my hood just to make sure it's that puffing and not something else, it makes me mad to see it is.

[mtskibum16]

Oh man...this is what I have to look foward to? What is the "breather?" Thanks. Aerospike, have you always had this sound? What does SF say? You should ask him while you are there.

[JCelica132]

go out and get a Turbonetics T3 gasket. That's what I did, fixed the exhaust leaking coming out of there. The copper gasket will melt between the turbo and manifold. It fits perfect. You just have to get the 4 bolt kind instead of the 3. Your local performance store should sell T3 gaskets. Also, you should look to pick up the oil bung gasket coming off the turbo.

By the way, I have a T3/T04B, but the manifold is still a T3 one.

[Boosted2.0]

On the breather issue, if you want to recirculate it you just need to get a nipple installed on your intake tube (right behind the filter) if you do this I reccomend routing it through an oil catch can to minimize the amount of oil you will be re-introducing into the system, as it will mean you need to clean your MAF more frequently.

[mrtomcat]

Originally posted by JCelica132
go out and get a Turbonetics T3 gasket. That's what I did, fixed the exhaust leaking coming out of there. The copper gasket will melt between the turbo and manifold. It fits perfect. You just have to get the 4 bolt kind instead of the 3. Your local performance store should sell T3 gaskets. Also, you should look to pick up the oil bung gasket coming off the turbo.

By the way, I have a T3/T04B, but the manifold is still a T3 one.

What's the oil bung gasket, what does it look like, where can I get it and how much?

boosted: would that be the same as the the oild catch can you are refferring to?

[mrtomcat]

are you talking about the model 30263 on the link below?

http://64.225.76.178/catalog/inst_accessories.html

[JCelica132]

Originally posted by mrtomcat
What's the oil bung gasket, what does it look like, where can I get it and how much?

boosted: would that be the same as the the oild catch can you are refferring to?

well I was having some problems with oil leaking from where the oil exits the turbo. There is the bung that attaches to the turbo, with a hose connected to it that drains into the oil pan bung. There should be a gasket between the bung and the turbo housing. It's like a felt material gasket, not metal. Turbonetics makes those too. Just ask for a T3 oil bung gasket and any performance shop should know what your talking about. It cost me $2.

[Alfy1]

I was thinking of installing these right before the cat, but wasnt sure if it would fit. http://www.atpturbo.com/Merchant2/graphics/00000001/Catalog%20Images/Flex%20Bellows/250-225225.jpg

http://www.atpturbo.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=SFX-FLX-002&Category_Code=FLX

Here is another picture to the oil return gasket...
http://www.atpturbo.com/Merchant2/graphics/00000001/Catalog%20Images/Gasket/GSK-OilReturnT3T4-225225.jpg

BTW do we need a gasket for where the down pipe meets the turbo?

[mrtomcat]

that looks like what I was thinking off for the downpipe to exhaust. No idea if it would fit but that's the idea that should fix the issue.

[fraugts]

I have that thing installed (flexible pipe) because of my issue with the downpipe not pointing out the way it should. Right after that, the 3" pipe...

[c2gas]

I have that too. Good idea and reduces vibration on the system.

[mrtomcat]

how do you attach it up to the exhaust (I still have the stock exhaust)?
Based on the picture there are no screws or anything to hold it and it's 6 inches long that sounds like it would be hard to fit in between?

Excuse my ignorance on this please

[Alfy1]

You have a muffler shop weld it in place...

[mrtomcat]

but how do you remove it if you ever have to take off the exhaust off the downpipe?

[Alfy1]

I was planing on welding mine between my flange and cat. Or any spot behind the flange. That way, incase I ever want to re-install my oem header, I can. I am just low on funds right now...

FRAUGTS maybe you have a picture you can show us?

[mrtomcat]

yeah fraugts.... or c2gas, let's have a picture :)

[fraugts]

Originally posted by Alfy1
I was planing on welding mine between my flange and cat. Or any spot behind the flange. That way, incase I ever want to re-install my oem header, I can. I am just low on funds right now...

FRAUGTS maybe you have a picture you can show us?

Pics are no problem, give me a day or two.
Mine WAS welded between the flange and cat, only now there is no cat, everything is 3'' all the way back from that point :gap:

I still cant talk about gains until I go, again, to the dyno place (probably this week)

[faultline]

Originally posted by mrtomcat
the smell comes from the exhaust leaking from where it's connected to the manifold. You need a new donut gasket.
I have the same problem. But as I said earlier the problem came back about a day or so later (after I went to the track).
That's why I think that some work needs to be done at the down pipe it's not aligned good enough to stay sealed.

I had that ai rushing noise as well until I got the manifold put back on (after the screws feel off and it almost fell off). That sound is now gone. You might want to take a look at it from underneath your car

I have the raspy sound around 2000 rpm. I was told that it's normal but I could swear that this was not there until a few weeks ago. I'm actually glad to know that someone else has the same issue makes me feel less insane.

The places I have to tighten up on my SF kit ( I own a 1zz Vibe and the turbo sits high it sight in the engine bay) There are like 5 8mm bolts to the exahaust side to the turbo, when they loosen, exhuaust leaks from there and make an exhaust leak noise. Also, the turbo spools a little notchy when its like this. These are easy to tighten.
There are 4 nuts to tighten on the turbo flange, if one falls off, it will leak exhaust and make noise. I dont have the donut gasket there, nor care too. I have had to tighten up these a coulple of times in the last 2 years.
Today I had to replace a missing bolt for the header to the motor. This is a 1st on that one.
The 3 down pipe bolts have always been tight.
As long as I have the recirculation vent button pressed in my cab area, I never smell exhaust , but if it is set on fresh air, I stlill smell some thing that I dont like even if no exhaust is leaking, and I believe it is the engine breather valve. I think I am going to attach a long hose to it and send it down toward the axle or some thing. ???????

[mrtomcat]

yeah, the breather needs to be routed somewhere else, I just noticed that it's pointing right at my firewall gromet where my avc-r wires enter the ****pit and that of course makes for a lovely smell as well, I need to get a better gromet for that.

It's funny that pretty much everyone has those same problems. It would be nice to find a solution and have that included with the kit so that future customers don't have to go through the same.

[aerospike2002]

I sometimes have actually exhaust coming into the cabin that I can see. When the moonroof or side window is open, you can see it being carried on the draft out the window.

[Alfy1]

Originally posted by mrtomcat
yeah, the breather needs to be routed somewhere else, I just noticed that it's pointing right at my firewall gromet where my avc-r wires enter the ****pit and that of course makes for a lovely smell as well, I need to get a better gromet for that.

It's funny that pretty much everyone has those same problems. It would be nice to find a solution and have that included with the kit so that future customers don't have to go through the same.

How come you can't say ****-pit?

[CONTROL ONE]

Originally posted by Alfy1
How come you can't say ****-pit?

swearing is bad, mmmmmkay?

[Masayver]

I don't get the smell in my cabin if I have either outside air coming in or recirculating....only when my windows or moonroof is open.

[aerospike2002]

My car is REALLY sounding bad. I feel as if maybe the manifold has come loose from the head, the turbo-manifold connection is leaking and MAYBE the downpipe-turbo outlet connection is leaking.

I don't know - it's REALLY loud now - I cannot even hear a mobile phone or music with it on. I have a horrible headache after everytime I drive too.

The turbo will not even spool up anymore - watching my boost gauge, it goes from vaccuum up to 0 psi where it should start spooling at, and it just hovers there. Even at WOT.

I really hope this is not doing anything to my engine. More importantly, I hope this is not my engine itself. I can still distinguish the characteristic engine hum from all the other racket, and it sounds healthy at all RPM's. I know that's nothing to judge by. Where it sounds really bad though is right in front of me and I can tell it's the area directly in front of the firewall. There are popping and sputtering noises. Not sputtering like it has anything to do with the engine or the combustion process though. Hard to explain how it sounds. And RIDICULOUSLY loud - like I have no exhaust which, I suppose, functionally I do not with the leaks.

The one reason I think this still has to do all with the exhaust is because I remember how my car sounded when I forgot to put the gasket in between the axle connection and exhaust flange of my TRD exhaust. No popping and sputtering really - but maybe that's because it was much farther away from me, instead of just in front of me, and I could not hear it. It did have a really nasty sound though to it, like now. Just not as loud and I'm assuming that's because, again, it was farther away from the actual engine outlet and the exhaust gases were not travelling as fast because they had cooled. (Heat = energy = rate of movement)

I know nothing about vehicle engines and what not. Could this cause detonation? Even if the turbo is not spooling anymore? Does this sound like something to do with the engine? Is an exhaust leak on a turbo bad for the engine - especially since the exhaust leak is not allowing the turbo to spool? I actually have less power now than stock, and I'm assuming that's due to it running basically a N/A setup now off of a turbo-specific exhaust manifold.

[mrtomcat]

Originally posted by Alfy1
How come you can't say ****-pit?

that's funny!!!

[mrtomcat]

that sounds like my car was a few weeks back when my manifold was only hanging on one screw (I wonder if they'll block "screw", hehe )
I had a muffler shop fix that up and it all was better again.

[aerospike2002]

^^EXACTLY what I figured.

Was your turbo spooling at that point?

I had visions driving down the road today of the whole assembly just falling out on the road. Hehe.

Lock-tite should fix this just fine.

[mtskibum16]

Is everything cool now mrtomcat? Like aerospike said, was your turbo spooling while the manifold was loose? I would assume not. I bet that's the problem aerospike! Good.

[mrtomcat]

Actually my turbo was spooling just fine but my a/f were all f'd up, the car would constantly stall at idle or if i'd push the clutch for a few seconds. I had a loud whistle sound no matter if i'd boost or not.

The manifold seems to be holding fine now but my exhaust came loose again.

Lock-Tite might be the solution, I remember boosted using that when he isntalled the kit but I had some screw related issues and so we had to take the exhaust off and on several times, my guess is that that wore down the lock-tite plus the torque.

I think the flex hose idea is the best though...hey fraugts did you have a chance to take some pictures?

[fraugts]

I am currently having the exact same problem (whistling manifold). We looked at it, and it was loose (1 bolt broken). We took care of that, replaced the broken bolt, put some metallic silicone, and everything was fine. Two days later, I hear the same f*cking whistle (Im currently running with it). I'll try to solve this, again, this weekend.

About the flexible pipe pics, sorry, I dont have them yet (going under your car is not an everyday thing) :gap:

[mtskibum16]

Geez. We need to figure something out to solve this problem. I think the solution would be a combo of lock tite and (the biggy) a bracket for the the turbo/manifold to help take some of the stress off the bolts. Has anyone tried this yet?

[aerospike2002]

^^Nope, but I think you should be the first :)

Seriously bro, if you come up with one, I'll pay for it. We've got a lot of weight riding back there.

BTW, I've PM'D Boosted about his opinion on why the turbo is not spooling.

[mtskibum16]

Sounds good buddy! I will try to come up with a good support. We'll see what happens!

[Hetts]

Im going to be getting my SF kit within a few weeks here and have it on before spring... and its about time i start getting my .02 in on discussions and start learning as much as possible!

Anybody in here have their turbo manifold supported by having a brace welded to a few sides and then to a support somewhere? I know that if you get a cheaper manifold you have to do this or else the cheap ones will bend/crack from all the weight. Im thinking maybe all of the weight from the system is finding the weakest link, which would be the screws/bolts.

Anybody have the exhaust manifold stud kit sold here?
http://monkeywrenchracing.com/mwr_arp_stud_kit_toyota_1zz_exhaust_manifold.html

Im thinking that this could do a lot of good as well to help the problem of exhaust leaks.

All I can think of for now, lets keep brainstorming about this until we can come up with a solution that works... there are too many people here with this problem to just let it go! I wish I had my kit...

[mtskibum16]

This might work or at least help! Some of you turbo guys should try these out! They only list them for the 1zz but I assume that they would work for the 2zz right?

[faultline]

Originally posted by Hetts
Im going to be getting my SF kit within a few weeks here and have it on before spring... and its about time i start getting my .02 in on discussions and start learning as much as possible!

Anybody in here have their turbo manifold supported by having a brace welded to a few sides and then to a support somewhere? I know that if you get a cheaper manifold you have to do this or else the cheap ones will bend/crack from all the weight. Im thinking maybe all of the weight from the system is finding the weakest link, which would be the screws/bolts.

Anybody have the exhaust manifold stud kit sold here?
http://monkeywrenchracing.com/mwr_arp_stud_kit_toyota_1zz_exhaust_manifold.html

Im thinking that this could do a lot of good as well to help the problem of exhaust leaks.

All I can think of for now, lets keep brainstorming about this until we can come up with a solution that works... there are too many people here with this problem to just let it go! I wish I had my kit...

I have thought about getting the studs from mwr, but in 2 years, all i have done is tighten a loos bolt down there. The SF manifold is very beefy, i dont think it needs extra support. As far as the other losenning bolts, I go out and tighten them every couple of months..they are not always loose, but i check um...I have been too lazy to try lock tight, but that is probably a good idea.

[Hetts]

Faultline, i was looking at the people that have had problems with this kit, and you are the only one with a 1zz that seems to be having leak problems.... is this problem more specific to the 2zz's?

[zerocooll21]

hey Hetts, when did you order your kit??

[aerospike2002]

Originally posted by Hetts

Anybody in here have their turbo manifold supported by having a brace welded to a few sides and then to a support somewhere? I know that if you get a cheaper manifold you have to do this or else the cheap ones will bend/crack from all the weight. Im thinking maybe all of the weight from the system is finding the weakest link, which would be the screws/bolts.

Look up at my posts and also that of mtskibum16....he and I have been theorizing through PM on how to go about doing this. I think we may have a solution in a couple weeks here after he gets his kit. Stay tuned...


Anybody have the exhaust manifold stud kit sold here?
http://monkeywrenchracing.com/mwr_arp_stud_kit_toyota_1zz_exhaust_manifold.html

Im thinking that this could do a lot of good as well to help the problem of exhaust leaks.


The 1zz is not the same as the 2zz, is it? Bolt-wise, I mean? Those look schweet.....

[Hetts]

I bought the kit used from relentlessracer ;o) I cant wait... even though this thread doesnt seem like fun...

[mrtomcat]

just wanted to let you all know (in case you didn't read my other post) that I got the flex pipe put on yesterday. We were going to take pictures but since my engine died on me we didn't get to that point.
But I believe that's definetely one solution to the problem

[Alfy1]

Was there enough room to fit the flex pipe in front of the cat? Or did you have to move it back....

[aerospike2002]

tomcat,
You got the 3" inlet/outlet pipe from the link on the first page of this? That's the one I'm getting to....about how long was it?