2.4 Litre Exhaust Manifold Cover Warped

[captd201]

First startup of the year on my 1989 XR4 and I have the exhaust manifold squirting out water on the left side. Upon disassembly and inspection I find both the outside cover plate and the divider are slightly warped causing a water leak when under pressure.

Can these two, the divider plate and the exhaust manifold cover be repaired at a machine shop (milled true) OR do I need to just replace both of these items?

Regards

[David - WI]

They are usually about $15-$20 on Ebay... if somebody here doesn't offer you a set. I would think it would cost more to straighten them if you have to pay somebody to do it.

I probably have a couple of each in my storage unit... if I can find them, you can have them.

[OnPad]

Let's see how bad I get flamed for this one!

I don't know how bad the warp is, but properly torqued bolts will flatten some warp. A friend had his exhaust cover leaking last year. About half of the bolts were loose.

My experience with the heads on these engines, (which are much thicker than a ex cover) you will rarely find one used that is perfectly flat. I have installed new gaskets, and torqued down a set that most people would call garbage. They take me fishing weekly with no problems for the last 5 years. I haven't put a straight edge on exhaust covers, but I bet most used ones aren't flat.

[David - WI]

Yeah, if the bolts were loose, that tells you everything. If you can replace the gaskets and get it to seal... done.

[tlwjkw]

new gaskets and clean (including all holes chased and bolt threads)... torqued in proper sequence and values.. if they still leak then "they" are tha problem........

there is jus so many folks around that don't take tha pains of installin' those pieces right..... jmo.

[captd201]

I just purchased a brand new in the box divider plate thru Ebay. The exhaust cover plate (the one with the big hole in it for the water cooled regulator)is a bit more rare with only used ones for sale presently and I am sure most are not straight either. So I will wait for the divider plate to arrive to see how well it matches the cover.
Thanx for all the input and suggestions,

[tlwjkw]

ya get jus tha inside piece?

[captd201]

Presently purchased a brand new divider plate that was easy, the exhaust cover plate is not as easy to find but have hopefully purchased a used one as that is all I can locate. Hopefully it is usable !

[pcrussell50]

What causes these things to warp?
Normal heat from recreational use?
Normal heat from racing/hard use?
overheat?

-Peter

[tlwjkw]

i've always believed tha installer has a big part.. lotta bolts, sequence can "easily" get outta whack..... but over heat can be a big factor also.......... jmo.

[David - WI]

I would guess any time you lose water pressure under power... that exhaust divider gets very​ hot.

[pcrussell50]

Related… memory fades since I’ve only done this once but Isn’t there a polymeric strip down the edge of the divider? Amazed at how durable that bit is.

-Peter

[pcrussell50]

Deleted duplicate… apologies

[Carter Powell]

If you c an't get a good cover, let me know. I have a guaranteed perfect one. And a divider plate.

Carter Powell

[captd201]

Thanx Carter, will keep that in mind, I picked up a used one which is in very good shape and surprisingly straight and I am just waiting for delivery of a brand new divider plate I am hoping all will line up and fix the problem.

Best Regards