Compression Ignition Addict
Join Date: Oct 2010
Location: Deerfield, VA
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Check for cracks FIRST, carefully look over flex joints and connection points on up pipe for soot (a flex mirror is indispensable). Check down pipe and up-pipe flanges for soot.
If you think a flange is misaligned, loosen everything, up-pipe to manifolds, (BTW, LS inner bolt a biotch) up-pipe to turbo clamp, Down pipe turbo clamp, and loosen turbo bolts.
Make sure clamps are FREE of flanges, shake clamps completely loose.
Align and tighten down pipe first, then up pipe to turbo, then up-pipe to manifolds, then turbo base bolts.
Having the turbo loose allows the turbo to "float" into position as you tighten your clamps. The up-pipe to manifolds have ball couplers which seal easier slightly misaligned, plus you can tweak them slightly utilizing the "flex" in the assembly.
My ultimate guess however is you have a crack in the up-pipe assembly somewhere, those clamp couplers on the turbo don't just loosen, they are pretty tenacious.