Hi all.
My 1.6TD is sounding like it has a blown exhaust. A very very nice man at
Stradey Motors in Llanelli had a look and we found 1 sheared exh manifold stud, 1 missing exh man. stud and non standard cheap bolts sheared on the manifold to turbo flange......plus one original stud sheared on here as well.
The great man in Llanelli fixed me up so I could limp home to Doncaster.
Question.....how difficult is it to get the rest of the manifold nuts off without shearing anymore ? or any recommendations for garages in the Doncaster area ?
The engines done 95K but normally runs OK so am I better off having a new/recon cylinder head rather than trying to get the sheared off stud out ?
Steve
1990 1.6TD Komet
Exhaust manifold/Turbo studs & bolts
Moderators: User administrators, Moderators
Once the manifold is off, you should be able to extract all of the remaining studs, clean up and refit new studs, the thick washers and proper lock nuts.
One or two might need drilling out, if they are broken-off flush, which in situ, won't be fun, but can just a bot be done I reckon...
Ditto the turbo flange, these 12mm poly headed set screws are expensive parts, if engine has been driven a lot with a poor turbo/exh flange seal then both parts will need facing off... It all depends on how good the head i ... _Manifolds
https://club8090.co.uk/wiki/Pa ... ine_Damage
https://club8090.co.uk/wiki/Te ... bolts/nuts
https://club8090.co.uk/wiki/Te ... ting_faces
and elsewhere in the Wiki, browse diesels engines.
The manifold to head studs and nuts can come loose if not tightened in correctly, need to be corret parts with those thick washers, exh manifold will possibly be distorted if been running without all the studs and nuts, ditto turbo flange.
Because it requires a lot of restraint, first try removing the turbo bolts whilst in situ, coming down from above with a long extension and a flexi/powerbar.
Owise take the exh manifold and turbo 'complete' off the head... then see to removing the turbo (12mm bi-hex socket; the manifold will thenneed supporting in a very strong vice when removing those bolts... they are done up to about 46 Nm, but can be very hard to undo after years of heat.
One or two might need drilling out, if they are broken-off flush, which in situ, won't be fun, but can just a bot be done I reckon...
Ditto the turbo flange, these 12mm poly headed set screws are expensive parts, if engine has been driven a lot with a poor turbo/exh flange seal then both parts will need facing off... It all depends on how good the head i ... _Manifolds
https://club8090.co.uk/wiki/Pa ... ine_Damage
https://club8090.co.uk/wiki/Te ... bolts/nuts
https://club8090.co.uk/wiki/Te ... ting_faces
and elsewhere in the Wiki, browse diesels engines.
The manifold to head studs and nuts can come loose if not tightened in correctly, need to be corret parts with those thick washers, exh manifold will possibly be distorted if been running without all the studs and nuts, ditto turbo flange.
Because it requires a lot of restraint, first try removing the turbo bolts whilst in situ, coming down from above with a long extension and a flexi/powerbar.
Owise take the exh manifold and turbo 'complete' off the head... then see to removing the turbo (12mm bi-hex socket; the manifold will thenneed supporting in a very strong vice when removing those bolts... they are done up to about 46 Nm, but can be very hard to undo after years of heat.
The 80-90 Tech Wikipedia Your 1st port of call
1.9TD Syncro Doka / Syncro Kastenwagen / 16" Kombi Camper
Syncronaut No. 1
Re:Exhaust manifold/Turbo studs & bolts
Many thanks Harry
Luckily (or not) the Turbo flange bolts undo easily.....when I got to Wales only 2 were still in and they were sheared, yet it was not blowing from that flange. It is the manifold ones I think will be a sod to undo.
I will order the studs, nuts,washers gaskets etc and have a go when they are here.
Thanks
Steve
Luckily (or not) the Turbo flange bolts undo easily.....when I got to Wales only 2 were still in and they were sheared, yet it was not blowing from that flange. It is the manifold ones I think will be a sod to undo.
I will order the studs, nuts,washers gaskets etc and have a go when they are here.
Thanks
Steve
You know the turbo to flange ones are about £13 ea.? 
Check the bottom of the maniold flange to turbo flange for cracking in the corner (see picture linked above in Wiki), if fine/hairline crack should be OK
No gasket between turbo and manifold, but they need to be pretty flat...
Spend some time flatting manifold face if distorted... https://club8090.co.uk/wiki/Tu ... installing
Wind studs in tight, loctite if want to belt'nbraces, nuts done up to 25 Nm or thereabouts. Remove rust/crud from area that washers float aginst (the lugs) so manifold pulls up well.
Note that the whole manifold moves around relative to studs through No.2's holes, other holes are quite a bit oversized by design, to allow expansion, hence the thick flat washers. So final tighten these two first after nipping all of them up.
Make sure you use the turbo exhaust flange to block support bracket.
Check the bottom of the maniold flange to turbo flange for cracking in the corner (see picture linked above in Wiki), if fine/hairline crack should be OK
No gasket between turbo and manifold, but they need to be pretty flat...
Spend some time flatting manifold face if distorted... https://club8090.co.uk/wiki/Tu ... installing
Wind studs in tight, loctite if want to belt'nbraces, nuts done up to 25 Nm or thereabouts. Remove rust/crud from area that washers float aginst (the lugs) so manifold pulls up well.
Note that the whole manifold moves around relative to studs through No.2's holes, other holes are quite a bit oversized by design, to allow expansion, hence the thick flat washers. So final tighten these two first after nipping all of them up.
Make sure you use the turbo exhaust flange to block support bracket.
The 80-90 Tech Wikipedia Your 1st port of call
1.9TD Syncro Doka / Syncro Kastenwagen / 16" Kombi Camper
Syncronaut No. 1
Thanks again
The Turbo support bracket was new to me.......there is none fitted so I will have to find/fabricate one...same with the heat deflectors
Yes I know about the Turbo flange bolts....high stretch bolts so I understand
I wet to dig out my old faceplate for the flattening but it has been in the back of my shed for about 20 years since I last used it so probably needs scraping and flattening before it is right so the glass plate method will be used I think. Try and get my mind back to my fitter training back in the mists of time.
Well I have plenty of info there to go at and will have a go.
Steve
The Turbo support bracket was new to me.......there is none fitted so I will have to find/fabricate one...same with the heat deflectors
Yes I know about the Turbo flange bolts....high stretch bolts so I understand
I wet to dig out my old faceplate for the flattening but it has been in the back of my shed for about 20 years since I last used it so probably needs scraping and flattening before it is right so the glass plate method will be used I think. Try and get my mind back to my fitter training back in the mists of time.
Well I have plenty of info there to go at and will have a go.
Steve
The Turbo support bracket was new to me..
CJ at Syncrospares might have one, presume it helps take the weight off those studs as well as reduce stress in the manifold turbo joint due to the (accelerated) weight
The 80-90 Tech Wikipedia Your 1st port of call
1.9TD Syncro Doka / Syncro Kastenwagen / 16" Kombi Camper
Syncronaut No. 1
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Plasticman
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Easy like this.
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... fold-1.jpg[/img]
Horrible looking mess
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... ifold3.jpg[/img]
Could have helicopiled them all as I have the kits but was enough meat to tap out to 3/8unf-unc
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... ifold4.jpg[/img]
Mike
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... fold-1.jpg[/img]
Horrible looking mess
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... ifold3.jpg[/img]
Could have helicopiled them all as I have the kits but was enough meat to tap out to 3/8unf-unc
[IMG:800:600]http://i42.photobucket.com/albums/e308/ ... ifold4.jpg[/img]
Mike