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Wednesday, May 22, 2013

Author:	Topic: 02 gtx 4tec water leak
admjr33	posted: 6/24/2012 12:29:37 AM Finally after 6 weeks......done:-) had to cut the last 3 bolts with a die cut grinder and a rasp wheel. Once cut everything went smooth, was running 30 minutes later.
admjr33	posted: 6/17/2012 4:10:28 PM .....
admjr33	posted: 6/16/2012 2:29:04 PM Ok got the right socket now. Got all the bottom bolts out and 3 on top. The other 3 on top are rounded. Any suggestions
admjr33	posted: 6/9/2012 8:00:03 PM So effin disgusted. 4 days of trying and only three bolts out. They will not budge. I tried heat with iron then with apropane torch still no luck. Dont know what else to do except take the plunge at the dealer :-(
David_HX	posted: 5/31/2012 5:46:15 AM Heat the Heads of the Trx Bolts w/ a 1000W Soldering Iron to break down the lock-tite
TLR	posted: 5/31/2012 12:20:49 AM LOTS of plastic in the engine compartment, watch where you throw flame TLR
Johnny K	posted: 5/30/2012 9:51:42 PM 1/4" drive and breaker bar.. sure it's not a 3/8".. if it's really 1/4", surprised that didn't break.. JK
admjr33	posted: 5/30/2012 9:30:47 PM Well i have the correct 6mm 12 pt torx socket 1/4" drive and a breaker bar but can only get 3top bolts off the others are extremely tight. Cant even see the bottom ones.....lol. Afraid the socket will slip off and strip head.... Any suggestions. Was thinking a little heat on the manifold bolt area
admjr33	posted: 5/27/2012 7:31:23 AM K will try torx socket today
Pale Rider	posted: 5/26/2012 9:20:43 PM it should be a torx socket, get the right size and youi should be good to go... you can remove the manifold without moving engine...
admjr33	posted: 5/26/2012 9:04:05 PM ok, i got a real good one on ebay. super clean looks brand new. no reserve i got the final bid in for 41.00. just got it on wednesday. now, it seems really hard to get to the lower bolts, and the 12pt 6mm socket is slipping off real bad, does this manifold come out itself or does this motor have to be removed
David_HX	posted: 5/23/2012 1:33:56 AM There are plenty used manifolds on e-bay
garygarnett	posted: 5/22/2012 1:26:46 PM Buy the newest one possible as they do tend to corrode thru. I had mine 2002 gtx corrode thru near the J pipe attachment.
David_HX	posted: 5/16/2012 4:31:00 AM Don't attach a cold water flush hose to a still hot engine. Bad things happen.
admjr33	posted: 5/15/2012 6:19:20 PM Found one but no part numbers. Its off a 2004 rxp. mine is a 2002 gtx 4 tec.
admjr33	posted: 5/15/2012 6:08:24 PM Ok cool thanks. I will call tomorrow.
Pale Rider	posted: 5/15/2012 5:34:31 PM Check with Rob or Glenn to see if they have any used in the shop. if not look here for an idea: http://www.ebay.com/sch/i.html?_from=R40&_trksid=p3872.m570.l1313&_nkw=4+tec+exhaust+manifold&_sacat=See-All-Categories wow those are over 500 new... :0 check the part numbers when looking for used for correct fittment.
admjr33	posted: 5/15/2012 4:46:52 PM If i can figure out how to post a pic i would show you...lol
admjr33	posted: 5/15/2012 4:36:58 PM Ok thata what i thought. Any ideas what a good used onenow might cost or should i contact ppg
Pale Rider	posted: 5/15/2012 8:31:13 AM ok, I gotcha now. The manifold itself broke. wow, that`s the first time I ever heard that happening. well not seeing what`s what, I guess it wouldnt hurt to try. as long as it is just the exterior part of the water jacket and running a bead around the broken piece. The real question is how did that happen and are there any more cracks in the manifold that can`t bee seen until cooling water passes thru. I`d also be concerned of any internal leaks. after the repair I would pressurize the cooling passage in the manifold to see if it hold pressure. you can either do it with water or air. If it were me, I`d be looking to just replace it with a known good one and ride...
admjr33	posted: 5/14/2012 10:53:20 PM The elbow was screwed into the broken piece and hanging from the hose. I loosened the clamp and took the elbow and piece off the hose. The elbow is intact and still screwed into the circular piece that broke off the bottom of the manifold. it will fit flush back on the manifold, my question is, can this be welded back on, i have a heliarc machine at work that i can tig weld it with or do i have to replace the manifold Thanks Anthony
Pale Rider	posted: 5/14/2012 7:29:11 PM did you remove the broken piece yet?
admjr33	posted: 5/13/2012 9:40:21 PM Ttt
admjr33	posted: 5/12/2012 11:31:33 PM I have the elbow in hand with the threaded piece still connected. It snapped right off the bottom of manifold
Pale Rider	posted: 5/12/2012 9:52:00 PM that elbow fitting for the bottom hose should be a threaded fitting. you`ll need top remove the exhaust manifold and try and ez out that broken piece. get a replacement and screw it in....
admjr33	posted: 5/12/2012 5:27:23 PM Pale. There are 2 hoses about 6 inches long near the exhaust outlet. One on top one on bottom. They go into the log near the rear of motor. The bottom one where rheos elbow goes into thethe log is broken clean off the log. Can this be tig welded on or does the manifold have to be replaced.
Pale Rider	posted: 5/9/2012 9:43:18 PM are all the hoses in place? clamps tight? nothing torn? need a better description of where, feel around under, is it closer to the front where the 3/4 hose attaches to the fitting?
admjr33	posted: 5/9/2012 8:42:27 PM Looks like water flowing from side of manifold. Almost like a hose, not a crack spray...very strong flow. Is there a freeze plug on these manifolds that migt popped
Pale Rider	posted: 5/6/2012 4:42:03 PM ok, we can rule out crack from freezing. sounds good, let us know... :)
admjr33	posted: 5/6/2012 11:45:54 AM Thanks pale...i will check today when ii get to dock. This was first ride of season but it was winterized and stored in a heated 60 degree garage all winter
Pale Rider	posted: 5/4/2012 7:49:31 PM If I`m understanding you correctly: look at exhaust cooling hoses at front exhaust manifold fitting, then look at the smaller hoses at the exhaust manifolds to J Pipe at the V band connection. if they look ok and check out, fire up the ski on the hose and look for water leaks in the exhaust manifold/log itself. It`s been awhile, but if memory serves me, the jet pump water intake pushes water to cool the exhaust only. The 4tecs are closed loop cooling. on SC models the routing goes to from the pump to intercooler, to front fitting under front of exhaust manifold, thru the exhaust log, out the 2 smaller hoses and into the J pipe, out 3 small holes in J pipe and into the water box and exit. NA 4tecs, same routing except no IC... Good luck, let us know what you find. is this the first time ski was run for the season? if so was the ski winterized properly? the exhaust log may be cracked if you do not find obvious leak... use an inspection mirror and have a look under the exhaust manifold...
admjr33	posted: 5/4/2012 7:23:10 PM Ran last weekend on river and almost sunk come to find out water is spraying in like a hose on side of motor near exhaust manifold... Any ideas?..

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Topic:	02 gtx 4tec water leak
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