My boost leak was the plastic manifold along the left side where the seam gave way. As the leak was spread over a large area you couldn't feel it with your hand, or hear it, but bubble leak tester showed the leaks.
I used tie wraps around the manifold which helped quite a bit, this should hold it until the new manifold comes next week. Under boost the manifold would flex and separate at the seemd the tie wraps hold the seam together, but there are still leaks. At least it is drivable. I am glad that I have my aluminum manifold as back up. I have a feeling that those people that built their engines, and installed the plastic manifolds are going to have problems, especially when boosting over 20psi. I am tempted to epoxy the seams of the new manifold as a safety measure!
The plastic intake did not come out until 2005. Some early 2005's had the aluminium intake that the 03 and 04 share.
The reasoning behind why alot of folks went to the plastic was.
lighter than the alumi
doesnt act like a big heat sink
smother inside compared to the alumi
plus it has some sort of quirky wedge that the alumi doesnt have that is suppose to help with air flow.
Of course it was cheaper for DCR to manufacture
I have a feeling over time it will start to show its age from the heat that builds up under the hood. My opinion of course.
I would check with Tommy at Haynes to see if he has any kickin around: http://www.haynesspeedshop.com/Store...&cat=39&page=1 if anybody needs one. The plastic intake manafolds are very inexpensive to replace. You can even pick one up at your local DC retailer.
The plastic manifold could have pop revits install around the seams, the epoxy could be used to fill the seam, which would take care of most of the problem. The thing that bothers me is NYLON 6/6 was used to make it, with a maximum operating temperature of 200 deg.F, and is for indoor use! This material may degrade in short order, my manifold was in for 6 months before it went. The last few days here in California we have hit 97 to 100 deg., and in bumper to bumper traffic you know under the hood is over 200 deg. F. Had the manifold been made of true composite the temp and durability would not be a concern.
Ok Time to chime in,,, this manifold won awards for its design and construction. If I remember right,, it is not glued or welded,,, basically it was compressed together,, and vibrated,, to generate heat, to fuse it together,,, ok I guess it could be considered welding,, sort of. Mine was the second to go on an 03,, I had the 50trim on when I installed it,, it sees 16psi min,, 26-28 or race gas,, it has outlasted 2 bottom ends,, and two trannys. Could you have gotten a defect,,,, yes,, you are the first I have read of this,,
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Plastic Manifold split at the seams!
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