Failed Manifold - Turbo Gasket

[DPJ]

Arse!

The (ATP supplied) exhaust manifold to turbo gasket has failed on my car. I can see a 9mm wide gap where a piece is missing. A little too much power methinks.

Please could I have an informed suggestion on what I should use as a replacement? Dealer std gasket?

Can I reuse the bolts - new from ATP 4 months ago?

 

[PhilW]

Gasketless? Just make sure the flanges are nice and flat.

 

[DPJ]

Gasketless? Just make sure the flanges are nice and flat.

Nice idea, but I really don't want to remove that manifold to tidy its flange up. Similarly, if that turbo comes off, it's not going back on again...........

 

[DPJ]

Anyone?

 

[wild willy]

Try using silicon mate, Blue Flame swear by it for all their high temp gaskets and it will save you hours of dismanteling and refitting. Its rated at 750 degrees.
Failing that i'd use a stock gasget from the dealers.

 

[MarkE]

Try using silicon mate, Blue Flame swear by it for all their high temp gaskets and it will save you hours of dismanteling and refitting. Its rated at 750 degrees.
Failing that i'd use a stock gasget from the dealers.

Even the high-temp sealant we use at work is only rated at 300deg C - they must be using something special?

 

[techie]

They tend to blow out when the manifold to turbo bolts come loose then it creates a hotspot where its blowing, all the bolts tight?

 

[DPJ]

They tend to blow out when the manifold to turbo bolts come loose then it creates a hotspot where its blowing, all the bolts tight?

No, they are still tight, Ross. I've read elsewhere people have had trouble with aftermarket (ATP? ) gaskets. I'm just waiting for a standard VAG one to turn up and I'll pop it on at the weekend. Running round with Revo off until then.

 

[DPJ]

So little jobs turn into bigger ones.

When I fitted my ATP manifold before Christmas last year, I had no trouble removing the OEM manifold to turbo bolts. They were replaced with new ATP supplied bolts which were properly torqued up.

I set to this morning and liberally soaked the three (new) bolts in penetrating oil - and left them - and soaked them again - and left them etc.

Then, without undue force, gently I started to undo them. The first bolt snapped straight away.

I now have to remove my turbo to take the broken bolt out. I am stuffed for time to do this during the next six weeks due to various commitments. I have put the car back together and it is blowing a tad more than it did before I broke the bolt. I can borrow Mrs DPJ's car to do my long commute, leaving her to potter around in mine.

Not a great situation. When I find a couple of days to set to, the car is then off the road until it's fixed. I have been through every scenario in my head. Buy a run around while I sort mine, hire, big turbo, get shot..........Cars, love them and hate them - it gets more critical when you start seriously modding.

................Arrrrrrrrrrrrrrrghhhhhhhhhhhhhhhhhhhhhhh

 

[Feel]

Can you get a pair of molegrips or small g clamp over the turbo and manifold to keep it tight while she pootles about?

 

[DPJ]

Can you get a pair of molegrips or small g clamp over the turbo and manifold to keep it tight while she pootles about?

Phil, yet again you prove why you are valued round here.

Manifold + turbo flange must be 60mm + so grips are out. A couple of drilled plates and a hefty bolt & nut on the outside might help.......

 

[DPJ]

It's occurred to me this morning that the ATP bolts are longer than OEM because the manifold is thicker. Also, if the 'front' bolt snaps, I'm going to have to replace it with a stud into the turbo with a nut on top, because that bolt won't come out without removing the exhaust manifold.

Has any idea what spec the bolts / stud / nut would need to be?

 

[m0rk]

If you stud the turbo, will you be able to fit the manifold? Not sure there's enough space?

But then all my jiggling was with a bigger turbo

 

[DPJ]

If you stud the turbo, will you be able to fit the manifold? Not sure there's enough space?

But then all my jiggling was with a bigger turbo

You could be right, Mark. Isn't the eliminator the same height flange to flange as the K03S?

What's easiest to solve the front bolt issue, ATP manifold off or DP off?

 

[m0rk]

You could be right, Mark. Isn't the eliminator the same height flange to flange as the K03S?

What's easiest to solve the front bolt issue, ATP manifold off or DP off?

Yeah, same height, and once bolted up, the DP doens't have 2" movement that you'll need.

I think the answer you're looking for is 'both' to come off (which is a pain, as that then means the centre section too

 

[DPJ]

Yeah, same height, and once bolted up, the DP doens't have 2" movement that you'll need.

I think the answer you're looking for is 'both' to come off (which is a pain, as that then means the centre section too

But no need to take the doors off?

In light of my gasket failing and what's said here, do you think it might be worth popping an OEM gasket into Jonah's before heat has it's effect on bolts etc?

 

[m0rk]

I'm pretty sure the one I fitted was an OEM one anyway (can't remember if it had a VW logo on it...)

good idea though, will suggest it

 

[DPJ]

I'm pretty sure the one I fitted was an OEM one anyway (can't remember if it had a VW logo on it...)

good idea though, will suggest it

It didn't come with the ATP manifold?

 

[m0rk]

yeah, one with turbo, and one with manifold - but I'm sure they were OE

 

[DPJ]

The one I got from the dealer this week hasn't got any maker markings on it.
06A 253 039 E - and it's 2 ply