Got the hoses all out this morning, they are soaked with oil so I suspect the seal has been leaking for a while, so I bet the engine has been drinking engine oil for a while. Since she starts (started) on first kick I'm not worried about plugs or injectors, but everything else will need washed out along with an oil and filter change.
Got the three manifold bolts off with a bit of work after a soaking, but as soon as I put the ring on the exhaust bolt I knew it was fekked. That crunch as the ring refuses to bed down, then the massive play on the spanner. Cleaned it up but nut just rounded instantly. Balls.
Nut-splitter ordered up should be here tomorrow will just destroy the bastards off.
 
I agree. The other two nuts are okay, justt seized. I'll give them a bit more gas and heat, and yes, Im going pick up a 14mm hex.
The third one is buggered though. I got the splitter on it this morning but as one member said in here it doesn't work too well on flanged bolts and the splitter just rode up rhe nut so it wouldn't split fully.
I'm a bit stuck and thinking I'm going to have to SOS my local landy man.
 
BigJock2005 said:
I agree. The other two nuts are okay, justt seized. I'll give them a bit more gas and heat, and yes, Im going pick up a 14mm hex.
The third one is buggered though. I got the splitter on it this morning but as one member said in here it doesn't work too well on flanged bolts and the splitter just rode up rhe nut so it wouldn't split fully.
I'm a bit stuck and thinking I'm going to have to SOS my local landy man.
Click to expand...
Can you get an Irwin extractor in there? These
 
Last edited:
Hmmm... they're interesting. I could get one in no problem, except maybe the rear one. I'll try an ordinary socket and if it works I might pick up a 14mm and give it a go.
Rusted and seized steel exhaust bolts must be the bane of every home mechanic, and have been for the 25 years I've worked on cars. If brass exhaust nuts are up to the job, as they seem to be judging by the number of people who've used them successfully, then it's amazing that they don't fit them as standard. But hey, what manufacturer cares about a DIY mechanic or any vehicle after it's left the forecourt...
 
BigJock2005 said:
Hmmm... they're interesting. I could get one in no problem, except maybe the rear one. I'll try an ordinary socket and if it works I might pick up a 14mm and give it a go.
Rusted and seized steel exhaust bolts must be the bane of every home mechanic, and have been for the 25 years I've worked on cars. If brass exhaust nuts are up to the job, as they seem to be judging by the number of people who've used them successfully, then it's amazing that they don't fit them as standard. But hey, what manufacturer cares about a DIY mechanic or any vehicle after it's left the forecourt...
Click to expand...
If you use an Irwin extractor then consider that nut or bolt as scrap as they cut in to the head to get a grip, they are not for day to day use.
 
The Irwin worked a treat. I put the 16mm extractor over the nut and firmed it up in place with a G-clamp. I put three 1/2" extension bars together onto a 1/4" adapter (the Irwin is a 1/4" square) and offered the whole piece up from below. Using a 24" torque wrench set to 160lbs I had to put a foot against the front wheel and grunt. Think I've pulled my shoulder. There was a very loud crack (which always makes me crap myself) and I expected to find a broken adaptor or bar, but to my delight the stud had cracked free. The Irwin tapped off and damage to the nut was actually quite minimal (see 1st picture) but I think if it had been terminally seized then it would have been wrecked.
Note on the second picture the effects of the Clarke nut splitter - it shows how the splitter rides up over the flange, so really not effective.
I removed with a ratchet and I'm glad that's over. On two of the studs the nuts are seized so tight, the stud came loose not the nut. But all three are out now. I have no idea how I am going to get enough grunt on the new nuts to get them torqued up.

stud and nut.jpg stud and nut 2.jpg
 
BigJock2005 said:
The Irwin worked a treat. I put the 16mm extractor over the nut and firmed it up in place with a G-clamp. I put three 1/2" extension bars together onto a 1/4" adapter (the Irwin is a 1/4" square) and offered the whole piece up from below. Using a 24" torque wrench set to 160lbs I had to put a foot against the front wheel and grunt. Think I've pulled my shoulder. There was a very loud crack (which always makes me crap myself) and I expected to find a broken adaptor or bar, but to my delight the stud had cracked free. The Irwin tapped off and damage to the nut was actually quite minimal (see 1st picture) but I think if it had been terminally seized then it would have been wrecked.
Note on the second picture the effects of the Clarke nut splitter - it shows how the splitter rides up over the flange, so really not effective.
I removed with a ratchet and I'm glad that's over. On two of the studs the nuts are seized so tight, the stud came loose not the nut. But all three are out now. I have no idea how I am going to get enough grunt on the new nuts to get them torqued up.

View attachment 155317 View attachment 155318
Click to expand...


New nuts dont have to be that tight at all, plus they will most likely be crimp nuts so self locking
 
It's likely that in the not too distant I'll fit a VGT as part of an overall performance upgrade. I am hoping some standard (new) 15mm steel nuts will do the job until then.
 
Got the intercooler out today - took me about 2 hours (see separate thread).
So the inlet pipes from the turbo have a lot of oil in them. There isn't very much in the intercooler itself, just a trickle appeared when I held it up.Inlet manifold seems clean. No sign of any metal anywhere, so I'm quite relieved and reckon I had a lucky escape as the turbo's been leaking for some time, but thankfully only failed outside my driveway.
I'll wash out the intercooler with petrol tomorrow and let it dry for a few hours (hoping we get some sun!) but the hoses are just manky and gunky so I'll take the opportunity to get a shiny new red silicon set. Recommendations welcome!
I'll get everything rebuilt tomorrow ready for the hoses arriving on Tuesday, and it'll be startup time Tuesday PM...

intercooler.jpg inlet hose.jpg
 
Just to let you all know that I completed the job earlier this week. New turbo in, bolted up with new gaskets and nuts, all hoses and intercooler flushed out with petrol and dried off, oil and filters changed. She pulls like a train now, so I'm very pleased. 75 miles down and no visible leaks, or anything from the exhaust, so here's hoping.
Have to say very pleased with London Turbos - even though they say return for p/x within 14 days I just called them and they agreed to accept in a bit later than that, so I'l get my £75 deposit back!
If I hadn't had so much trouble with the exhaust bolts, it wouldn't have been a difficult job at all.The Irwin extractor saved my bacon there.
Thanks for all the comments and advice everyone.
 
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