Little Dog
A2OC Donor
Operation save little dog (Albert).
- Thread starter Little Dog
- Start date
Little Dog
A2OC Donor
Success, got the stubborn nuts off the EGR pipe flange. Now there will be no more progress before the tools and parts arrive.
How I removed them is shown here https://www.a2oc.net/community/index.php?threads/g-052112a3-hot-bolt-paste.49195/page-2
How I removed them is shown here https://www.a2oc.net/community/index.php?threads/g-052112a3-hot-bolt-paste.49195/page-2
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Little Dog
A2OC Donor
Everything I needed landed today. So I've been busy and have coiled the two stripped threads and the one next to the tandem pump which didn't feel good when I ran a tap down it.
Ideally I would like to coil the third hole at the back, it felt a bit soft when I tested it to 10 Nm. To get at it I need to remove the wiper motor which could do with a clean anyway. It looks like two nuts and two screws. Are those nuts and screws on / in to captive studs and inserts? I don't want to have to take the dash out to refit the wiper motor. Thanks.
Details of how I did the job later, the angle drill was not great to use and keep vertical but I had a fix for that.
Ideally I would like to coil the third hole at the back, it felt a bit soft when I tested it to 10 Nm. To get at it I need to remove the wiper motor which could do with a clean anyway. It looks like two nuts and two screws. Are those nuts and screws on / in to captive studs and inserts? I don't want to have to take the dash out to refit the wiper motor. Thanks.
Details of how I did the job later, the angle drill was not great to use and keep vertical but I had a fix for that.
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Little Dog
A2OC Donor
The manual said remove 4 screws and the wiper motor comes out. It took some wiggling around but I got it. This how I fixed the threads, first the tools:
Used joiners 6mm drill bush held it firm to the head to ensure the drill was square. The drill was vicious and pulled into the alloy so the joiners drill collar set the depth. Used lots of fluid, blowing out and applying fresh fluid throughout drilling and tapping.
I have two M6 coil kits, one with a second tap and one with a plug tap. I wanted to use 2.5 D inserts with the tangs left on the thread but I couldn't tap the holes deep enough. So I went for 2 D which meant the screw threads would be very slightly longer than the inserts are deep. Second tap.
Plug tap, depth set to suit 2 D insert. When I get there the thread is cut to the correct depth.
Hole ready for an insert
Knock out tang, I left them in there.
M6 first tap to remove any tang burrs, some inserts were a little stiff to screw into right at the bottom. M6 tap solved the problem.
Job done
Used joiners 6mm drill bush held it firm to the head to ensure the drill was square. The drill was vicious and pulled into the alloy so the joiners drill collar set the depth. Used lots of fluid, blowing out and applying fresh fluid throughout drilling and tapping.
I have two M6 coil kits, one with a second tap and one with a plug tap. I wanted to use 2.5 D inserts with the tangs left on the thread but I couldn't tap the holes deep enough. So I went for 2 D which meant the screw threads would be very slightly longer than the inserts are deep. Second tap.
Plug tap, depth set to suit 2 D insert. When I get there the thread is cut to the correct depth.
Hole ready for an insert
Knock out tang, I left them in there.
M6 first tap to remove any tang burrs, some inserts were a little stiff to screw into right at the bottom. M6 tap solved the problem.
Job done
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dj_efk
A2OC Donor
Tapping is very satisfying - more so when you do up the fixing tight and it holds firm!
Little Dog
A2OC Donor
Yes the last one was, as show in the pictures. By then I had a process. The first one I did was one of the highest risk jobs I’ve done. Muck it up and I could need a new head.
Yes all the repairs tested to 10 Nm ?. Relieved rather than satisfied.
CrispyEdd
Member
Crikey
CrispyEdd
Member
Bravo ? brilliant job
Little Dog
A2OC Donor
Spent all of my car repair hours today replacing a leaking turbo inlet pipe O ring, not sure how that happens on the suction side?
Had to smear plumbers silicone grease around to get the pipe to slip on, got there in the end.
Never paid much attention down there before, surprised how small the turbo is.
Had to smear plumbers silicone grease around to get the pipe to slip on, got there in the end.
Never paid much attention down there before, surprised how small the turbo is.
kp 115
A2OC Donor
The o rings get flats on them where they seal with age,
You may find the silicone causes the charge hose to blow off the fitting.
Little Dog
A2OC Donor
It’s on the suction side, yes the O ring that came out was square like. I tried to fit the new ring several times with rubber grease; needed something more slippery.
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Little Dog
A2OC Donor
CrispyEdd
Member
awesome!!!
CrispyEdd
Member
Beautiful sound. You've done great look at the stunning cover ?