Failed Manifold - Turbo Gasket

[DPJ]

I've found out the size of bolts I need to get by emailing ATP.

Do I just buy standard items or should I try to get some thing special (in terms of metallic composition) ?

 

[Feel]

I would see if their is something similar sized for a similar application that you can get from the dealer if I were you, they are usually better quality that the stuff you can get from the factors.

I heard that the S4 nuts are the ones to get, if it stops them backing off or seizing has got to be worth it. I wonder why it's not common to lockwire (wire melts?) or use other mechanical locking washers.

 

[DPJ]

I would see if their is something similar sized for a similar application that you can get from the dealer if I were you, they are usually better quality that the stuff you can get from the factors.

I heard that the S4 nuts are the ones to get, if it stops them backing off or seizing has got to be worth it. I wonder why it's not common to lockwire (wire melts?) or use other mechanical locking washers.

Cheers Phil, these are 10mm x 70mm 1.5 screws with a 17mm head. I was going to go to a fixings supplier. I just wondered if there was something that would cope with the heat from the turbo better than HT Steel.

(Yes I spotted the thing on S4 nuts too.)

 

[Feel]

Difficult, I would suggest going for stainless ones, but stainless expands more than steel when it's heated...

Try AET?:

http://www.aetturbosonline.com/catalog/product_info.php/products_id/171

 

[DPJ]

Difficult, I would suggest going for stainless ones, but stainless expands more than steel when it's heated...

Apparently SS isn't as strong as a lot of HT steel.

This is now officially frustrating me and interfering with my plans to fix it this weekend. I've learned a lot about bolts.

I managed to acquire some M10 x 70mm shiny bolts today, marked 8.8 which are medium carbon steel, quenched and tempered. However, when I got home I had a look at the broken (ATP) supplied bolt and its marked 12.9 - which is alloy steel, quenched and tempered. Where the **** I get some of them tomorrow I have no idea. I'm having no luck online. To add to the confusion, the OEM bolts from the standard manifold aren't marked conventionally. They've got RIBE (which I guess is the manufacturer) and S D.

I really don't want to take my turbo off, remove the broken bolt(s) reinstall and then fit bolts that are going to fail.

 

[DPJ]

So this afternoon, I mainly had my hands down the back of my engine.

See the separate bolt technology thread here but

look at the state of this lot! Good new 12.9 grade bolt on the left, mashed ATP 12.9 bolts 2 & 3 (~3 is actually bent) . The bolts really are in a shocking state. As for the gasket

Turbo off tomorrow morning to extract the TWO broken bolt ends.

 

[DPJ]

Good job I took m0rk's advice and took the manifold off, there is virtually nil movement on my DP this time. Blueflame must have tightened something else up when they repaired it.

 

[m0rk]

lucky.... good job you managed to wriggle it free past that stud

 

[DPJ]

It ain't coming out!

I'm going to break the stud extractor in a minute........

 

[m0rk]

can you heat it up at all?

 

[DPJ]

I'll give that a shot.

 

[DPJ]

Plenty of heat




and then broke the extractor.

 

[lofer]

Thats not good!

 

[m0rk]

a precision engineering shop should be able to run a pillar drill down it for you, and leave you just the thread left

 

[DPJ]

a precision engineering shop should be able to run a pillar drill down it for you, and leave you just the thread left

Thanks Mark - I'll do that. I've just given up drilling the extractor, its bloody hard!

 

[ibizacupra]

spark erode it out.

 

[Feel]

How much is a GT2X again?

 

[DPJ]

How much is a GT2X again?

More expensive than the GT28RS Eliminator I've just bought.

Manifold's off Phil. Shall I get the jugs out? (measuring variety)

 

[Feel]

I've just read your other thread. Nice one.

 

[wild willy]

Dpj i feel for you mate. I fitted my hybrid turbo to the LCR on the week end.... not a walk in the park with very tight bolts, Especially the manifold to turbo bolts. I had to apply a lot of force to shift them and when they release they go with a fair crack. Touch and go as to whether they snap or not. The sealing washers prevent effective useage of wd40 etc. Turbo and manifold removal... not for the faint hearted.