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here's my $0.02 based on the most recent rebuild.... Posted by DET17 [Email] (#1254) [Profile/Gallery] (more from DET17) on Thu, 9 May 2013 06:35:53 In Reply to: The Dreaded Turbo Exhaust Manifold Leak, Judge Edo, Wed, 8 May 2013 12:25:40 Members do not see ads below this line. - Help Keep This Site Online - Signup |
Here's my experience...YMMV.
On the last 2 Elring HG jobs I did (87 and 91), both had the LONG stud on #1, closest to the firewall, snap off when torquing the exhaust mani to 18 lb. ft. Luckily, both times the engine/trans was on my workbench, not in the beast.
I replaced ONE stud only in EACH case. I heated several others as hot as I could get them with MAPP gas...but the aluminum head is a fantastic heat sink and it runs away, so I suspect you never get the "delta T" correct to free the steel stud from the aluminum head.
FWIW, the eEuro "exhaust stud kit" is crap IMO. The studs look like poor excuse material from China....probably recycled Vegas and Pintos from the 70's. The OE studs are much higher quality, probably guten Deutsche stahl (steel). If they "RING" as the man said, don't change them. Chase the threads with an M8 die, buy new locknuts. Smooth sheet metal face of the gasket goes against the Cast iron...composite side against aluminum.
NEXT - check your exhaust mani for warp while it is out! My 91T manifold had a pronounced warp at #1 (near firewall)...it was standing proud around 1mm AWAY from the head. Took it to my local auto machinist and he used the precision sander to flatten it ($35). Reassembled everything "loose", including fitting the turbo drain, then torqued all up. Don't be surprised if your exhaust leak is around #1.....wouldn't surprise me if this is endemic of the SAAB casting.
Good luck Judge!
_______________________________________ DET17
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