finding vacuum leaks

clubman_dan · Post by **clubman_dan** » Sat May 26, 2007 12:37 pm

just picked up the gaskets, i can see what you mean now rich, i have a heat shield with a gasket either side between the plenum and inlet manifold.
i will order a second gasket so i can put one wither side if needed.
the guy on the parts desk gave me 10% off so it was slightly less painful on the wallet.
picked up some new flexible ratchet spanners yesterday too, so hopefully they will come in handy when i get started.
wish me luck.....

rpruen · Post by **rpruen** » Sun May 27, 2007 4:30 pm

clubman_dan wrote: picked up some new flexible ratchet spanners yesterday too, so hopefully they will come in handy when i get started.
wish me luck.....

The ratchet spanners will come in handy for sure

I hope the bracket is not fitted to your car, that will make life so much easier.

Oh and Good Luck

although I hope you don't need it.

Richard

clubman_dan · Post by **clubman_dan** » Thu May 31, 2007 10:24 pm

made a start this evening, spent about 3 hours working, i managed to remove the plenum, exhaust downpipe and i have almost reached the stage of taking the turbo out.
i am taking photographs of the stages to do a how to guide, for anyone who may take the task on in the future.
cheers
Dan

clubman_dan · Post by **clubman_dan** » Fri Jun 01, 2007 3:51 pm

went out this morning all refreshed and ready to go..
started undoing the nuts which hold the turbo to the exhaust manifold, 3 came off no problem, the fourth rounded off!
it had to be the one which is hiding in the corner too, no access (virtually) around it, nut splitter couldn't get in the gap very well, i have tried drilling it, filing and sawing, no luck!!
i have spent all day on this one nut, and its not off! to make matters worse the stud is now decimated too, so that will need changing

today sucked.
anyone have any bright ideas? this needs to come off..

pol · Post by **pol** » Fri Jun 01, 2007 3:56 pm

Hmmm, what an arse...

Sleep on it... Then attack again when refreshed. Heat is good if you can get in there... Angle grinder too.

pol

clubman_dan · Post by **clubman_dan** » Fri Jun 01, 2007 4:04 pm

tried the grinder, it doesnt fit in the gap

actually i should say it might just reach, but it would hack everything else in the area to bits too!
i might try getting the dremel down there, just need to find the flexible extension.
i hope its worth it in the end!

clubman_dan · Post by **clubman_dan** » Sat Jun 02, 2007 9:02 am

got that bastard thing off! managed to get it off at about 1130 last night, my mate bought his decent drill over and some cobalt drill bits and we just drilled away, then beat the crap out of it with a really long screwdriver and a lump hammer!
hopefully progress will be better today!

clubman_dan · Post by **clubman_dan** » Sat Jun 02, 2007 6:01 pm

didn't get much done today, went out on the bike instead.
managed to get the turbo out though and almost have the manifolds off, just a couple more nuts to get off, i need to buy a 1/4 inch drive ratchet first though.
ended up using a jack to push the engine forward in order to get the turbo out, the hbol never ceases to amaze me with the bullshit they print!
they must get special cars, or have mechanics with superpowers or something.
hopefully more progress tommorrow

clubman_dan · Post by **clubman_dan** » Sun Jun 03, 2007 11:03 pm

managed to get the manifolds out today! the old gasket looked pretty sorry for itself.
i had that bloody bracket though! managed to get it off with out removing the starter motor, just removed the heatshield and the brackets that sit at the end, and i was able to get a socket over the bolt.
just been cleaning all the surfaces ready for rebuilding, now i just need to remember where everything goes!

pol · Post by **pol** » Mon Jun 04, 2007 9:23 am

Yep, getting the turbo out, i dont think is possible without using a jack. Or taking the engine out. I use the scissor jack.

Good luck with the gaskets. Putting back together is the easy bit, you'll be idling smoothly in no time! Just mind those threads when sandwiching the 2 parts of the inlet manifold. It's a shit feeling when you've done all that then you realise you've stripped the thread! Quite a low torque, use that 1/4 ratchet you're buying!

pol

clubman_dan · Post by **clubman_dan** » Mon Jun 04, 2007 10:33 am

just got the manifold back on, going to go over to volvo and order a new downpipe to turbo gasket and turbo to manifold gasket. may as well change them while its all apart, the old ones look pretty scabby.
hopefully they will arrive tommorrow and it will be back in action!

clubman_dan · Post by **clubman_dan** » Fri Jun 08, 2007 6:09 pm

finally done! still have a tiny air leak somewhere, but it runs much much better now!
just need to go to the private test track to see if it will pull above 90mph, i bloody hope so!
i will get a how to guide written if anyone else dares to try it!

clubman_dan · Post by **clubman_dan** » Sat Jun 09, 2007 12:50 pm

just started it up with a stone cold engine, needle is hovering halfway into the white and its idling badly like before!
once its warm the needle barely hovers above the bottom and it runs better, but not perfect.
i thought it was finally sorted but i was clearly wrong

any ideas? its getting on my nerves now after a week of working on it.
probably going to sell it and get something else

VanDerGraaf · Post by **VanDerGraaf** » Sat Jun 09, 2007 1:41 pm

For shit's sake man, that is just not fair!
All that hard work, really sorry to hear that.

Don't sell it just yet- if you can't source the problem then you would have to sell it like it is- which surely means you won't get much for it at all.

If you're still having this problem, surely that points to the reason being something more simple, as you have now eliminated the biggest job?

clubman_dan · Post by **clubman_dan** » Sat Jun 09, 2007 3:35 pm

i am going to soldier on with it, there must be a simple reason for it, just got to find it. i guess all that work was not in vain, at least its done now.
back to work..
i think i might check the intercooler, in case its got a hole in it.