Manifold Leak Suggestions Please

[Laird Scooby]

Originally Posted by Steve 940

Many thanks for all those recent posts from you all, really really appreciated.

I really must just say since joining this forum I can't believe the friendly support and invaluable knowledge that's out there, previously I had an Allroad with 'issues' with inlet manifold flap motors, VW /Audi forum support was almost non existent.

Anyway, lots to take on board, have tried pushing some work back to new year, so week before Xmas I might be able to get this sorted. Hopefully the job will go well, but being aware or pre-warned of potential pitfalls should hopefully give me a fighting chance.

Haynes indicates draining coolant system, I presume I don't need to drain the whole thing, just enough to allow turbo removal. A full flush of radiator and heater matrix is on my long list of preventative jobs to do, that have since been overtaken by more pressing problems😀

Mark, No I didn't order from FRF, Brookhouse are only around 10 miles or so from me, and were very good getting parts sorted for me when I was sorting my soggy rear end so to speak

Should be here mid-end of next week, they had most parts but manifold/head studs coming from Sweden.

I have the GCP links to Weblisher parts list, but don't really feel confident enough in being able to decipher exactly what I need, although I seem to have so many tabs open on sections that I have issues with.

Cheers
Steve

Just a suggestion Steve, if you're draining the cooling system, do the flush and antifreeze renewal at the same time. Kills two birds with one stone that way!

[Steve 940]

Good sensible advice, if I've got to drain it anyway.

Have large bottle of genuine Volvo concentrate already, but I don't think I can cope with doing both things at once.

Will use time whilst getting 'close and personal' doing the turbo removal to inspect coolant hoses, as I had in mind to make sure I had replacements to hand before doing the flush.

Cheers
Steve

[baggy798]

Originally Posted by Steve 940

Well that was expensive.....

£187+ for 8 head studs/nuts, 4 studs/nuts turbo to manifold, 3 studs/nuts for Turbo to front pipe, oil feed pipe gasket and o ring, plus 8 crush washers for banjo fittings.

I know they're genuine Volvo head / manifold studs, but £7+ each for a stud and similar for a single nut, whilst coming from Sweden in 6-8 days, I do feel a tad 'shafted'.

If it fixes it then I suppose I'll forget the cost, although it does stick in the throat a bit, when specialist fasteners suppliers have studs of all sorts for around 60p for steel or £1 for stainless.

Only trouble is you can't find out the exact sizes needed till you actually do the job, so as I need mine off the road as little is possible I need to get all the bits to hand before starting.

Oh well, that can be the better halfs Xmas pressie 😀😀

Cheers
Steve

Yeah, you've been done.

Stock manifold studs/nuts are nothing special, except the 4 nuts that bolt the turbo to manifold. According to turbopricks:

The ones for the head are M8x1.25. 50mm long, 10mm shoulder.
The ones for the turbo downpipe are M8x1.25, 40mm long, 10mm shoulder.

For the mani head nuts you want flanged copper ones.

[baggy798]

You reusing the exhaust gaskets?

[Steve 940]

Hi Baggy 798

Many thanks for your post, was looking last night and fastener supplier had loads of various studs but obviously need to know sizes, not just M8 etc but length of short thread, shoulder with no thread length, and long thread length.

Test today only indicated leaks both sides of turbo, so I'm hoping to not need to actually pull manifold, as I use it daily, I didn't want to have it off road waiting for parts, so just ordered manifold/head studs and nuts, plus new gaskets.

Hopefully manifold won't be cracked, and they can stay on shelf in garage for future if needed.

I did post on general motoring on home page, as the turbo has quite a few banjo fittings each needing 2 crush washers, obviously buying separately is not cheapest option, was thinking of getting a box of assorted sizes of copper crush washers, although a bit wary as they're bound to be cheapo Chinese product, and sizing/quality may not be consistent.

Just thought the amount of supposed single use crush washers on the car, would be way more cost effective.

Cheers
Steve

[kiloran]

Originally Posted by baggy798

Yeah, you've been done.

Stock manifold studs/nuts are nothing special, except the 4 nuts that bolt the turbo to manifold. According to turbopricks:

The ones for the head are M8x1.25. 50mm long, 10mm shoulder.
The ones for the turbo downpipe are M8x1.25, 40mm long, 10mm shoulder.

For the mani head nuts you want flanged copper ones.

Cor, nice nuts!

[Steve 940]

Fastener supplier I found when digging around, of course only found it after spending an arm & leg on Volvo ones!!!

https://www.spaldingfasteners.co.uk/manifold/

Loads of other fittings for all sorts of things.

Cheers
Steve

[Laird Scooby]

Originally Posted by Steve 940

Fastener supplier I found when digging around, of course only found it after spending an arm & leg on Volvo ones!!!

https://www.spaldingfasteners.co.uk/manifold/

Loads of other fittings for all sorts of things.

Cheers
Steve

I use them quite a bit for things, they have a fantastic range of stuff. I was still wracking my brain cell trying to remember the size of the studs when you announced you'd ordered the bits at £OUCH-MUCH and didn't want to rub it in so to speak.

[Steve 940]

That's good to know Dave, I just Googled manifold Studs and nuts and they popped up, nice to know you've used them before, ink I will save their details.

I know they were going to be expensive from Volvo, but I suppose I've mellowed a bit since, at least if I do it properly, then I shouldn't have to worry about it for a while.

Also should hopefully give me some comfort in doing it myself and not paying a fortune to a garage, assuming I do it correctly😀

Will use the fastener company I think to source new bleed nipples for the calipers I'm refurbishing, just need to get a thread checking my tool, never need much of an excuse to get another shiny tool!!

Cheers
Steve

[Laird Scooby]

Originally Posted by Steve 940

Will use the fastener company I think to source new bleed nipples for the calipers I'm refurbishing, just need to get a thread checking my tool, never need much of an excuse to get another shiny tool!!

Cheers
Steve

A digital vernier gauge for measuring the diameter of the thread and a thread pitch gauge to confirm the pitch of the thread. I think they're M10 x 1.25 but i could be wrong and/or thinking of a different car.

Also BiggRed will have bleed nipples :

https://www.biggred.co.uk/

You'll still need to know the thread size and pitch though, screw pitch gauges often come in tap and die sets :

https://www.ebay.co.uk/itm/322367211514

https://www.ebay.co.uk/itm/174943139010

Crikey, those digital verniers have come down in price since i got mine!

I seem to remember seeing bleed nipples on Spalding Fasteners site but they are only for a few models (MGB rings a bell) and i suspect one of the site owners just happens to own the type of car they fit.