Hole in turbo manifold

[RickVRS]

Well I've found out why the noise on boost had changed and found out why my rolling road results were poor. A bolt in the turbo manifold had been botched. What I can see if it's snapped on tightening and the previous owner had exhaust pasted the top of the bolt in.

This has come out meaning I have a big leak.....when revving the engine you can feel the air coming out.

So looks like a turbo out job.

Just what I needed!

[chicken_eyebrow]

Sorry to hear that, at least you know the turbo itself isn't duff though

[RickVRS]

Yea....I considered buying a ko4s and swapping it whilst it's off but ts too much money when I have a service and a cambelt and tax all due next month.

I've got a mate doing it next week so will see how it goes I guess. Should run more power than the 205bhp I ran on the rollers eh

[missingmyvrs]

that will be the cause of low figures !!! as he had only just replaced the turbo!! shame it wasnt done properly but atleast you will now be sure it is

i will recomend when you have the mannifold off you port it as this see's good gains like a high flow manni

hth glad you found the issue

[Liverpool-Lad]

Ahhh. Interesting. Get it sorted and over to John Clarksons

[RickVRS]

it has a high flow mani on already? i may give it a quick port but im mainly interested in getting the car running again! im driving it now but making sure the turbo doesnt spool up.

will dyno it once its fixed and should see about 230 i think

[Vrs wrc 71/100]

I have both gaskets here mate genuine vag. Bought them from the stealers. If you want them £6 plus postage. It's the turbo to manifold gasket and the Manifold to head gasket

[RickVRS]

if you can get them posted tomorrow as the car is needing fixing mid week then you would be an legend.....pm me your paypal address and amount

[Vrs wrc 71/100]

I can get them out today buddy yes. I am posting a spring to another member today so will do it then. My PayPal is [email protected] as for the postage I'm not sure. A couple of quid would cover it for certain I'm sure

[LexVRS]

bad luck mate i dont think anyone saw that coming oh well get it fixed and back to full health in no time haha

my tax, mot and cambelt have all been for feb so i know how the budget feels mind you now i can focus on mods and getting this boost surge fixed

[RickVRS]

yea its one of those things.....hopefully it will be an easy job for my friend to take the turbo off and rebolt it up.....not sure how they all bolt together, where its threaded and snapped or what.

[TrevorB33]

if its one of the bolts that goes through the manifold into the turbo you might be able to do it in situ with just the manifold off

[RickVRS]

Yea it looks like it's been overtightened and snapped off in the housing. Were thinking it needs removing and the snapped bolt drilled out. Do you know where I can get a new bolt from?

[TrevorB33]

Yea it looks like it's been overtightened and snapped off in the housing. Were thinking it needs removing and the snapped bolt drilled out. Do you know where I can get a new bolt from?

ah yeah if its snapped off in there you might have trouble, try a skoda dealer or TPS or audi seat etc

[RickVRS]

Yea need to double Check or has been snapped but no other reason the top half of the bolt would have been exhaust pasted I'm there. When I did my dyno with a run on full boost it's obviously exploited the weakness.

[RickVRS]

well turbo bolts 51p each and the gaskets off here for £6.....hopefully not be too much o have teh turbo refitted.

Anything else ill need?

[RickVRS]

hi guys,

Quick question as im starting to understand this now...a bit. I have new bolts that bolt the turbo (im guessing wastegate) on to the exhast manifold at the top. Its 3 bolts fed down in to the housing.

Now ive tested this on an old set up i have and its fine but when i drop the bolt in my car it drops all the way in but there seems to be no thread.....its like my bolt isnt long enough. Could it be that as i have a high flow manifold on the bolts need to be longer?

[TrevorB33]

hi guys,

Quick question as im starting to understand this now...a bit. I have new bolts that bolt the turbo (im guessing wastegate) on to the exhast manifold at the top. Its 3 bolts fed down in to the housing.

Now ive tested this on an old set up i have and its fine but when i drop the bolt in my car it drops all the way in but there seems to be no thread.....its like my bolt isnt long enough. Could it be that as i have a high flow manifold on the bolts need to be longer?

you sure the thread just isnt completely gone i.e rounded off, wouldnt have thought a high flow manifold would use longer bolts, though im not sure

[RickVRS]

i dont know....you would think it would catch even just a little bit. Looks like it needs removing to check but luckily if i remove the exhause manifold it will be easy to see whats done without removing the turbo side

[TrevorB33]

i dont know....you would think it would catch even just a little bit. Looks like it needs removing to check but luckily if i remove the exhause manifold it will be easy to see whats done without removing the turbo side

just undo one of the other bolts in there and check your new one for length make sure its right

[RickVRS]

Good idea! Will do it tomorrow and see.

[kentphil1]

If the worst comes to the worst and the thread is gone, get a helicoil insert fitted - engineering shops dont charge that much to do it - some people will do it in-situ for a fee.

It could work out cheaper than a turbo overhaul by a long way. If your mate is in the trade he may even own a helicoil kit to do it himself - not hard to do.

Hope it helps

Phil.