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Date:         Sat, 23 Apr 2011 20:06:41 -0700
Reply-To:     Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Subject:      Re: Pesky Vanagon exhaust system.....
Comments: To: John Goubeaux <john@UCSB.EDU>
Content-Type: text/plain; format=flowed; charset="iso-8859-1";
              reply-type=response

hi, no sealant on the exhaust gaskets. ( they don't need it, and oxygen sensors can get ruined by some type of sealants )

sometimes, on that cast iron junction piece, it's normal to need double gaskets on one of the pipes ..like usually they 'forward cylinders' pipe . I've seen that a number of times. so see if that might make a better meeting of the pipes there with that cast iron piece.

nut type doesn't matter too much. non-copper ones tend to rust in place after a long time. Copper is a better material to use there for sure.

it's normal always to retighten all exhust fasterners after a few warm-up-cool-down cycles. Just don't break off any studs that screw into the heads or anything .. but for the nuts and bolts ....tighten them very firmly by hand.

always use copper anti-seize compound ( or aluminum, but copper is better ) on the theads of all fasteners on the exhasut system.

I suspect your aftermarket pipes might not fit that well. there is some tendency to 'normalize' after numberous heat cycles...then thighten nuts and bolts more.

see if two gaskets on the forward pipe isn't something that would help,. at that cast iron piece.

laying on your back under the ( van elevated some ) is a comfortable way to work on them. Creeper helps of course . I sure like that better than van on a lift where you are working with your hands over your head looking up . On a creeper ...things are right in front of you , nice n' comfortable. Or lay on a large piece of cardboard perhaps.

scott www.turbovans.com

----- Original Message ----- From: "John Goubeaux" <john@UCSB.EDU> To: <vanagon@GERRY.VANAGON.COM> Sent: Saturday, April 23, 2011 7:18 PM Subject: Pesky Vanagon exhaust system.....

> Any exhaust system experts have any advice to offer? I just installed a > new 2.1 engine in a 90 and ( with engine out) bolted on new exhaust > header pipes and the heavy elbow flange that joins them together on the > LH back corner. It was a bit of a bear to get em all to mate up > properly, but with a lot of loosening and tightening and coaxing I > thought I got em all snug ( poor fitting aftermarket parts I'm > thinking). Well after start up it looks like I have an exhaust leak at > one of the connections to the large elbow flange. Damm - I'm thinking > these were hard enough to mate with engine out, now I have to do it on > my back and looking up ! > > So are there any tricks here ? Use a gasket sealer along with the > regular flange gasket? Are regular nuts better than copper as it might > be easier to tighten them down more ? I used copper thinking they were > superior. Maybe I just need to use a bigger ratchet and tighten the crap > out of the bolts, at the risk of breaking a bolt though. Maybe it's not > uncommon to have to loosen/re-tighten them after a few heat/cool cycles ? > > Any sympathy and or suggestions appreciated. -john


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