92T Exhaust Manifold Leak

[ETCdude1]

I can always count on you guys for good advise. I replaced my turbo last year with an ATS CT27. I broke the manifold stud in the head closest to the driver's side (same one Lovehorsepower broke). The stud was replaced and the work continued. The stock manifold was milled flat, both on the head and turbo side. I had some slight fitment issues at the cat bracket due to the amount of material removed, but all went well. New seals/gaskets all around. All torqued to spec.

A year later the repaired stud loosened up and caused a leak. I tigtened it, but it still leaks very slightly, although not as bad. It is the classic exhaust manifold leak---only makes noise for a minute or two when the engine is cold.

Any advice (BGB no help)?
Can I change the manifold, without ripping out the turbo, elbow, cat, downpipe, etc? I suspect the manifold change will be like a turbo swap all over again. Not fun anymore.

Oh yeah a new manifold is almost $300 from Toyota !!

thanks..............

[MR2Jedi]

I have removed the exhaust manifold and the head without disconnecting the turbo from the DP and removing the turbo from the engine bay.
I suspended the turbo with a rope and hooks. I do have an ATS 3" DP, so it was easier to access the manifold bolts than with the stock primary cat in place.
Your manifold may have warped again due to the loose bolt. You might wanna use some thread locker on the studs/nuts/bolts to prevent it from happening again.

I had the same problem and resurfaced mine too. The only problem with the reinstall was the bolt hole for the turbo stay did not line up, so I had to enlongate the hole.

[BDSL]

Are you using the proper nuts? The locking ones so the nuts would not loosen while under heat and vibrations.

[ETCdude1]

Thanks for your help. I'll give it try. I did replace all hardware with factory parts. I did use some antiseize on the studs. Maybe that’s what caused it. I checked the other manifold nuts and they seemed OK.

Is there a plug and play header out there where the turbo fits like it’s still on the factory manifold?

[MR2Jedi]

CX Racing makes descent one.
MR2 Turbo Header/manifold