Exhaust manifold eaking bullhorn - Defender Source
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  #1  
Old May 4th, 2016, 06:45 PM
barjout
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Marc Bourget
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Exhaust manifold eaking bullhorn

Hi, Last summer I replace my turbo on my 300 Tdi for a hybrid turbo from Bell auto services and and since then the left bull horn is leaking and spurting black soot in the engine bay. I tried muffler ciment from Kleen Flo and lately some extra high temp silicone but it's still leaking. Any suggestions on what I should use to stop that exhaust manifold leak? I was gonna use cold weld but the temperature is way too high for that. According to my Pyro gauge the highest the temp will go is 562 degre celcius or 1043 fahrenheit.
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  #2  
Old May 4th, 2016, 07:07 PM
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John B.
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Clean it up really well with sand paper and then wash both sides of the joint (it needs to come apart first). After dry use a good exhaust cement filling the gap. Let fully dry and then allow to hot slowly before allowing the turbo to come on boost.
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  #3  
Old May 4th, 2016, 07:11 PM
barjout
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Marc Bourget
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I did all that twice. Cleaned it with brake cleaner, let it cure and then started the engine at idle for 20 minutes then turned it off to let it cool but same results twice. Still leaking. What brand do you call a good exhaust cement?
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Old May 4th, 2016, 07:14 PM
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Quote:
Originally Posted by barjout View Post
Hi, Last summer I replace my turbo on my 300 Tdi for a hybrid turbo from Bell auto services and and since then the left bull horn is leaking and spurting black soot in the engine bay. I tried muffler ciment from Kleen Flo and lately some extra high temp silicone but it's still leaking. Any suggestions on what I should use to stop that exhaust manifold leak? I was gonna use cold weld but the temperature is way too high for that. According to my Pyro gauge the highest the temp will go is 562 degre celcius or 1043 fahrenheit.
Always had good luck with this on my turbo cars upwards of 35-40psi.

http://www.amazon.com/Permatex-80697.../dp/B000HBNUDQ
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Old May 4th, 2016, 07:16 PM
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John B.
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Quote:
Originally Posted by barjout View Post
I did all that twice. Cleaned it with brake cleaner, let it cure and then started the engine at idle for 20 minutes then turned it off to let it cool but same results twice. Still leaking. What brand do you call a good exhaust cement?
You took the joint apart and filled the whole void between the turbo and the pipe?
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Old May 4th, 2016, 07:19 PM
barjout
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Marc Bourget
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But the temperature range is from 50-500 fahrenheit. It won't be enought as mine sometime sees 1042 fahrenheit do you think?
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  #7  
Old May 17th, 2016, 01:08 PM
kosma_r
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Jarek Bednarczyk
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I have the same setup and the same problem. The cement was blown after 1 week. I wonder if new bullhorns will be better than old ones.
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  #8  
Old May 19th, 2016, 08:16 AM
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1of40
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I recently replaced my worn turbo and horns with new. The net cost after selling the old unit was immaterial. The point is the new components seem to have sealed fine with the muffler cement.
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  #9  
Old May 19th, 2016, 09:18 AM
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Doug Crowther
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you should be able to get to 720 C.
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Old May 19th, 2016, 09:24 AM
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Clay, post up what product we used. I think it was the Permatex stuff?

Quote:
Originally Posted by 1of40 View Post
I recently replaced my worn turbo and horns with new. The net cost after selling the old unit was immaterial. The point is the new components seem to have sealed fine with the muffler cement.
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Present:
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Past:
1959 SII 88"- "The Little Green Beastie" last seen in NY
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  #11  
Old May 19th, 2016, 08:31 PM
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Michael
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Have you considered cut your own hi temp / pressure gasket? http://www.amazon.com/Mr-Gasket-9615.../dp/B00068OLEW
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