OK im getting really tired of this. Ive had an exhaust leak since ive had the turbo and i really cant tell what its from. It sounds like its coming from the headers but ive tightened them up and i still get that terrible sound. WHat can i do about this? I cant figure it out. Its not the wastegate bc ive tightened taht way up.,

 

well you should start seeing some black carbon build up around where the leak is. if you can't you'll most likely have to take it apart then you'll be able to see where it was leaking since you'll see where the black carbon is going past the gasket.

 

oh ok yeah its the headers then, ive tightened those up several times but i cant fix it. any ideas?

 

if you tightned it up to the correct torque specs and it still leaks then your gasket is bad or on backwards. might need to get a new one.

 

you need to machine them down. just kinda kiss it with a belt sander. should do the trick.

 

crap that takes forever to take it apart. i do not have a torque wrench so didnt tighten it to the correct torque specs.

 

yeah, but make sure you dont over-tighten things. youll get problems with your gaskets and cause more leaks.

 

crap this is annoying, im going to email rrm and see how mucha new gasket is.

 

i meant you have to machine down the header where it meets with the head. just take a belt sander to it and make everything smooth.

 

do you have the rrm headers? did oyu ahve to do that? i dont really want to mess with it like that, id rather jsut get a new gasket.

 

yeah its a pain in the ****....but just make sure thats where the leak is coming from first. you don't wanna take it all apart and have it just be one of the up pipes leaking or something.

 

i think i hear it coming from the middle of the headers and i see carbon above it on my the side of the valve cover, so hopefully it is the headers

 

yeah, i have RRM's header. i bought it used, so i figured itd be a good idea to do it anyway. i just noticed that when i got it, it was kinda nicked up and stuff where it meets with the head so i just sanded it down.

 

how tight are we suppose to tighten the rrm headers?

 

The problem will be the header flange plate is warped - this is a commen problem with most aftermarket header firms that when they weld the headers the flange plate will buckle. Some firms may or may not face them with a sander afterwards but we generally find this doesn't work.

We find with our RPW headers / Manifolds we brought in a special machine called a Shilko that we use specifically for re facing (Not sanding) the header flanges. We quite often actually have to lay the manifold down in between two blocks of steel and hit the centre with a large sledge hammer (Extreme) to straighten the bend out after welding as the bend like a banana.

If you keep tightening the bolts with this warpage you will eventually break the two outside studs and then the problems really start.

A lot of exhaust firms fit thick gaskets with lots of goo to stop this problem. If they are done right and machined properly youshould be able to use the origonal mitsubishi stock gasket (We have never had to change one yet) and a small amount of silicone (Not even enough to see it).

I cannot and let me clarify, am not specifically commenting on RRM product here. This is a generalised statement on exhaust manafacturers in general.

I would recomend anyone purchasing any header to always before fitment, get a straight ruler etc and place it across the surface of the flange and there is a gap there - get it fixed first.

Shameless plug - I think we all know what RPW does to there headers here!!!

David Thomas
www.rpw.com.au