Finally found that exhaust leak...

wallaka

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...and it wasn't the manifold. I figured it that the flange had eroded, so pulled the head to see the damage. Looked at the head gasket, and lo and behold, it's blown out at #4 on the passenger side. It's right where we could feel the exhaust coming out but we thought it was the exhaust manifold. After I got a new manifold and it still leaked, I got suspicious.

It is strange because the car ran fine. No skipping or anything. I only drove it once a year or so because I was stationed overseas so couldn't tell if it was down on power or not. Since the leak was on the opposite side of the water passages, it didn't use any coolant. I'm gonna go ahead and clean the pedestal and rocker shaft out tomorrow, and maybe port-match the exhaust and polish away some of the casting lines and such in the combustion chambers.

So anyway, now I need torque specs for the head. Also it has adjustable rockers (surprise!) so I need the lash spec. It should have hydraulic lifters but I didn't pull one to look at it.

Man it feels good to solve a problem. It'll be nice to be able to drive it again...it's been four years now.

EDIT: So I found a torque spec, 75 ft-lbs in 3 steps, is this about right?
 
Yes, but with pauses. 50, pause 20 minutes, then 65. Wait overnight for the crush to settle (it does slightly), then 75. Because I'm cranky and old I use waterproof grease on the front bolt that goes into the water jacket - not sealant.
 
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