"Scott Daniel - Shazam " <scottdaniel@turbovans.com> writes:

> 'the problem' is that the flanges warp over time, the pipes warp
> over time, sometimes - like if the pipes and flanges didn't' warp,
> the gaskets would last very well. They by themselves, the port
> gaskets, are not weak especially, unless someone put in el cheapo's
> or something.

Well, like a lot of things on this van there's evidence of some
hacking on the exhaust system.  I just studied the Bentley
illustrations of the exhaust, and the leak I have is at the "exhaust
manifold", i.e. the little cast iron two-into-one piece that's on the
right side.  Both gaskets on the engine side of that manifold were
leaking at the bottom.

> The studs and nuts notoriously are badly corroded, rusted, and
> stuck.  Getting the nuts off without breaking a stud off is 'the
> hard part.'

More evidence supporting the PO's claim of a new motor and head work:
the bolts on the exhaust system are all new!  The pipes are fairly
rusty though.

I unbolted the manifold easily, and the leak seems due to the fact
that the support brackets for the muffler are missing.  Someone bolted
a loop of strap hanger to the chassis on the left side, near the
tailpipe, and used one of those rubber donut hangers to support the
muffler there.  But this allows the muffler to bounce a bit, and seems
to have twisted that manifold a little so that the a leak developed.
In the Bentley it looks like the muffler is really supposed to be
supported in the center by the front engine mount, so that the entire
exhaust is rigid with respect to the engine.

Also the exhaust support bracket at the flywheel side, is just
dangling from the pipe it's not attached to the case at all.

> might as well convert to subaru

Well -- not quite there yet.  And still leaning towards the Zetec in
that case.  But we'll see.  I just reinstalled the oil filler tube,
using my homemade gasket at the flange, and that seems to have
resolved the leak there.  I've had a few cases of the oil pressure
alarm sounding when I'm slowing after a higher-speed run.  I installed
a new Mahle filter and 15W50 Mobil 1 oil, which I'm hopeful will
eliminate that.  Next step will be to get a pressure gauge on
there, but the oil I drained seemed thin so I'm hoping that's the
problem.

Allan
--
1991 Vanagon GL