1.6 Turbo Manifold Fitment Issues
 

Hey guys, I bought a used turbo setup a while back and I am finally starting the turbo install but have ran into an issue with the turbo manifold lining up and fitting onto the studs. I asked the previous owner of the manifold to see if he needed to do any modifications to fit, but he said he had no issues and it fit without any hassles. I just wanted to ask here before I start shaving the holes bigger to make the manifold fit if there are some tips on getting this on. I just find it weird that it worked with no problems for the previous owner but now it's giving me issues. I have tried to install it from the left side, right side and straight in but it just doesn't want to go in. Here's a pic below to get an idea of what I'm talking about. If you have any info on how to get this installed or any ideas, it would be much appreciated. Thank you.https://cimg7.ibsrv.net/gimg/www.mia...bb038c0cb6.jpg
https://cimg8.ibsrv.net/gimg/www.mia...a7ab519aa8.jpg

Flange warped maybe? I don't understand what your problem is, it looks like it should line right up. What exactly is it hanging up on?

manifold is warped, throw it away.

Is your heater hose hardline still installed? Looks like it is and in stock form attaches to one of your exhaust studs.

Drill the holes out one size larger...

It also looks like it mind be binding. Does it fit if you try to put it on straight? -instead of left side first. Some manifolds fit very tightly to the studs and have to go on perfectly straight.

Or as others have said, it could be warped. Put a straight edge on it to see.

look at the difference in the relief cuts...


( it also helps to install the manifold straight on, and not at an angle... )

Might be the worst photo angle we could have to help.

Even my cast FM mani did that a little. I had to open up the holes a little. Heat cycling does it. You will want to check the face for trueness.

Try relocating the outer top studs in one hole. Might be they didn't use those outer studs. Mine doesn't, but it's an older begi cast.

Yeah, i believe its warped from the info i got from others. I might just try to take a couple of studs off and install it that way.

I only put it on that way in the pic to get it to stay on so i could take a pic. I tried every angle possible and every way it should go in but had no luck.

Thanks for the help.

Don't even remove any studs, bring it to someone so they can mill it flat. Even if you get it on there it will not seal correctly causing a pretty massive exhaust leak

Ok, if im going to do that, i might just have the relief cuts done again too.

No, it's likely ruined because of those relief cuts, which were done wrong wrong wrong, its no wonder it flexed and warped, it is floopy as an uncooked sausage link.

This area:

https://cimg6.ibsrv.net/gimg/www.mia...6f2d748a32.jpg

Look around at some pictures of relief cuts properly done. It is possible to cut too much or in the wrong fashion (your case).

Sorry to bump this post from a couple months ago but I am dealing with this manifold having a leak on the top right of the manifold(by the more open relief cut). Do you think it's worth it to get the manifold milled by a machine shop or would I be better off getting a new manifold, most likely the tacotaco from ebay. Please let me know your opinions on what you would do. Thanks.

Yes.

OK, thanks, i'll probably go to the machine shop to have them mill the manifold.

I wouldn't redo the relief cuts. If there's any residual stress in the manifold it'll just keep moving in the direction it already moved (closing up the cuts). Just have the shop dust the face as minimally as they can and clean up.

So just ask the shop to shave off as little as possible but make it all even. Thanks for that tip.

Yes, machine shop.