Club 80-90 Forums

http://www.youtube.com/watch?v=f8l73bWTXPI

Any comments?

I was chatting with Christoph Boltze (VWPIX.ORG) and he told me is a very common failure, some bolts usually break and then happens that, I didn't realise, the only thing was sometimes when I stop the engine after 1 hour driving or so was a metallic sound from the turbo area... it was the exhaust turbine scratching the body... hope you understand some technical point in english are hard to explain for a spaniard!

I had one like this, best remove and bin the item and then replace with a new or good second hand one.

Hiya Victor ..... where have you been?

Hey Andrew!

Well just working and enjoying the weekends as good as possible... I am trying now to fix the van because maybe in two or three months I will return with my gf to Europe to work there... Selected countries are Netherlands, Germany and Belgium... I don't know exactly about the jobs there but I will try to know it as soon as possible.

What about you and your life, paddy?

What do you think about the post, the turbo?

I think the turbo might be broken Victor !!!!

Im still up in Annamoe but will be moving soon to South Limerick. Very flat Im fraid so nothing to play on like the mountains around here!!

I bought a Mercedes 300SE the other day to play with as well as the syncro!!

Thanks for the suggestion about the turbo, really, I didn't know it was broken.

So a MB 300SE... these old guys don't know what to do with €... sad!

Is that a Garrett or the the KKK ? I've a KKK that was very iffy in that joint, in fact I'm in two minds whether to use it...

Corrosion and/or poor cleaning up and re-assembly when it was rebuilt, as it looks like its been mullered a bit in places. Poor design in that area.

It is the KKK K14 I think now its called BorgWagner... I think I will buy again the KKK (because it is the original one) but before I have to clean the manifolds, install new gaskets, check all the bolts, nuts, and so on... A lot of work to do...

I's suggest you do indeed do that...

Check the exhaust manifold bolts, they're often loose, need to be the special ones with thick washers so that the manifold can move as it expands (No.2 is a clearance hole, the other three sets are extra large to allow movement, hence the gaskets being individual to the ports.

You may have trouble with the 4 specials holding the turbo to the manifold, one or two may break, use a well fitting socket and work at them, rust buster from underneath if they seem seized - they're £13 each! You'd need a heat resistant 12.9 hex socket cap to replace them with, or source some 2nd hand ones.
No gasket in there, just dead flat and true surfaces, you may find some cracking of that manifold at the corners of that turbo inlet port flange, those bolts are torqued to about 35 ft-lbs I think, prob. no more than 40, whatever it takes to get them out! Might be worth trueing the mating surfaces up too, the exhaust manifold can run at up to 3 x boost pressure.

HarryMann wrote:I's suggest you do indeed do that...

You may have trouble with the 4 specials holding the turbo to the manifold, one or two may break

Well were hard to move at the beggining but the tip was just unscrew a bit then I did use WD40, then screw again and wait then unscrew again but a bit more so finally the 4 bolts were unscrew in 30 mins more or less and in a good status

HarryMann wrote:No gasket in there, just dead flat and true surfaces, you may find some cracking of that manifold at the corners of that turbo inlet port flange, those bolts are torqued to about 35 ft-lbs I think, prob. no more than 40, whatever it takes to get them out!

There was a gasket, a metallic one, between the exhaust manifold and the turbo... the thing was I took the turbo out with the first exhaust section and then I cut the bolts because they were 100% rusted/bad[/quote]

Now the thing is what shop to buy the new turbo, I have asked for spare parts on Bernd Jaeger and people tell me Busschmiede works nice... I want to know how many time Busschmiede takes to send the parts and the way to pay... I think I will send them an email...

There was a gasket, a metallic one, between the exhaust manifold and the turbo...

See if you can find a good source then, they're not shown in ETKA and AFAIK, not installed ex-works, just perfect mating faces straight together to transfer heat evenly between the two.

But you've confirmed what I've been told, thin stainless gaskets can be sourced for retrofitting, possibly for when the faces are damaged...

these might be of interest...

http://wiki.80-90.co.uk/index.php/Techn ... ting_faces

http://wiki.80-90.co.uk/index.php/Turbo_-_Re-installing

http://wiki.80-90.co.uk/index.php/Turbo_-_Manifolds

There's some others there uunder Diesel engines too..

Thank you for the links, harryMann!!