Check this out, do the cracks around where the ex side of the turbo go hurt?

(the mostly rust free manifold came with the new turbo, the other is original stock)







The one that came with the new turbo appears to just be a refurbished used part, even has a crack in another area that mimics one of the big cracks in the manifold I removed. That manifold has some interesting parts as well, including two smaller versions of the cracks where the turbo enters it... WTF???

5/25/2009 5:19:45 PM

they are stress cracks from overheating or overtightened bolts, they will get worse

5/25/2009 6:31:35 PM

Pretty sure the big cracks in my old manifold are from overheating. Aside from the time spent on the road at 1100+ degrees in the past few months, I think was really too hard on it in November after picking it up (no EGT gauge yet) in Orlando and driving straight back. The small cracks could be related to this I suppose, since the cast iron might have already been a bit weaker at that point in the manifold (machining) and I am sure the whole thing was glowing hot.

The "new" (used) manifiold that came with the "new" (upgraded rebuild) turbo on the other hand- well it was probably treated similarly and thus began to develop its copycat cracks. Then when it was sandblasted the edges of the small cracks were worn away?

5/25/2009 7:12:18 PM

is the ring with the cracks in it separate from the housing? looks like two pieces

5/25/2009 7:14:14 PM

thats the wastegate passage maybe?

5/25/2009 7:29:05 PM

looks like to me that the ring is pressed in, but i doubt you would ever find a replacement one

5/25/2009 7:32:55 PM

Quote :

"turbo go hurt"

5/25/2009 10:02:53 PM

not an uncommon issue at all with cast turbo manifolds. dsm's are notorious for it. it won't really hurt anything, but like 69 said they'll likely just continue to grow until it completely fails somewhere. you can put a small cut perpendicular at each end of the crack to stop growth and mig or stick them with nickel rod, but it'll just be a temp fix at best. if you go this route, make sure you put a V slice into the crack itself also to get a good root and pre/post heat well.

that said, the used manifold you got with the new turbo appears to have suffered from over torqued bolts. the stock one look to be mainly caused by heat, though i would say they've been aggravated by excessive heat. looks very possible the engine it came off of suffered from a leaking/blown head gasket at some point or short heat cycles due to the white (steam/moisture induced) around the cracks.

kind of a toss up. i'd probably use the one on the left though. is there any sort of support used for the turbo/manifold other than the studs/bolts in the head? if not, you might want to add something. that would definitely help some.

5/25/2009 10:49:34 PM

Quote :

"dsm's are notorious for it."

Mine is really bad right around the wastegate (internally gated)

5/26/2009 7:23:03 AM

5/26/2009 8:43:30 AM

did you ever find one?

6/13/2009 7:48:02 PM

whole lotta crackz fo yo b0000st to leakz

6/14/2009 12:56:11 AM

A new one should be arriving soon from the UK...

6/14/2009 2:45:46 PM

why dont you have a local shop machine you one? probably cheaper and better anyway

6/21/2009 9:28:02 AM