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Need Urgent Help: Turbo Coolant Fittings

satanic

By satanic,
in Engines & Forced Induction

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satanic Grand Master

satanic

Posted
Posted

Hi

Just installed a new turbo tonight and went to try the coolant to see if there were any leaks. What do you know, the thing pisses the green stuff out like you're at the movies.

We've brought it down to the bolts going through the banjo fitting and into the turbo are completely different to what they are supposed to be.

Threads are different resulting in a "gap" that lets the coolant out. We've tried 1 set of copper washers, and we've even tried 2 sets of copper washers. No good!

Has anyone got ideas for a VERY VERY quick fix... I need the car ready for a wedding on Saturday so i'll be willing to try any option so long as it works.

Stan

Craved Grand Master

Craved

Posted
Posted

Stan ... your gonna be out of luck i reckon mate ..

you dont wanna be risking your engine over a leak like this, never mind not being able to bleed the system properly ..

tomorrow is friday, you should be able to get the new banjo fittings.

but

do they screw in easy? you dont have to force them??

how big is the leak? are you using the bolts that gop with the banjo fittings?

satanic Grand Master

satanic

Posted
  • Author
Posted

The bolts go into the turbo, but definitely not easily close to the bottom of the thread.

The leak is a drippage on one side, and a total mess on the other... so I think one side is OK and the other will need some serious gear to get going.

I am thinking that Enzed might be able to sort something out...

Chris, what about getting a few washers in there or even on thick one?

Craved Grand Master

Craved

Posted
Posted
The bolts go into the turbo, but definitely not easily close to the bottom of the thread.

The leak is a drippage on one side, and a total mess on the other... so I think one side is OK and the other will need some serious gear to get going.

I am thinking that Enzed might be able to sort something out...

Chris, what about getting a few washers in there or even on thick one?

wont help if the leak is through the thread or through the banjo fitting.

have you got copper washers on both sides of the banjo connection..

washer: banjo:washer:bolt ????

satanic Grand Master

satanic

Posted
  • Author
Posted

Yeah copper fittings in between everything like you have put...

I'm pretty sure it's coming out from the bit that is closest to the turbo and not the banjo. That is

Bolt; washer; banjo; washer; (leak is here); turbo

I only say this as there is an obvious difference in the bolt at this point when compared to the stock bolt. Also, there looks to be a gap. Looks like hte banjo washer isn't even sitting flush with the turbo.

Maybe a couple of smaller reducing washers to make it sit flush/

Bolt; washer; banjo; washer x 3 (or one fat one); turbo?

Craved Grand Master

Craved

Posted
Posted

need to be copper washers so that they are squashed to create the seal... if there is a gap where you state, try another washer .. if it reduces the leak then you might need some sealant in there ... where did you get this new banjo from?

did you test fit it before the turbo went in?

Craved Grand Master

Craved

Posted
Posted

the bolt might be too long for the hole, and causing the gap.. if this is the case then a washer should fix it... try fitting the bolt and see if it stops cos it seems to hit the end of the thread or no

Syphon Rising Star

Syphon

Posted
Posted

As above sounds more like the problem...would be unusual for the face on a banjo fitting to not be flat, or the turbo for that matter. spose it could happen.

Either bolt bottoming out or your being a pussy and not doing it up tight enough :P

The suggestion of leaking through the gaps in the thread is pretty much impossible when you think about it, well aslong as the copper washers are sealing correctly of course. Don't make me explain, its pretty obvious :(

BHDave Grand Master

BHDave

Posted
Posted

When you say the thread is different, do you mean different pitch and spacing? or just a longer threaded section so it is bottoming out?

I really hope you don't mean different pitch. If the banjo bolt is simply too long, grind a bit off it. You dont want to pack it with washers.

blind_elk Grand Master

blind_elk

Posted
Posted

Had a similar problem when I fitted a new turbo to my RB20 few years ago. Simply went back to the suppliers and got it sorted (bolt was too long, or maybe hole was too short).

satanic Grand Master

satanic

Posted
  • Author
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Thanks for the advice guys... I think the bolt is too long because in comparison to the original's thread it is a bit longer.

Well we're going to see if we can sort it out - if not we're kinda fuxored!

satanic Grand Master

satanic

Posted
  • Author
Posted

It's a custom hi-flow system...

The housings are the same as the stock turbo, but the "middle section" is completely different ot the old turbo.

Hence the different bolts.

Thanks

S

satanic Grand Master

satanic

Posted
  • Author
Posted

OK spark of genuis went through my mind as I was sifting through some parts in my garage. Stumbled upon a "press on hose fitting" or "hose barb" with a thread on it.

We are thinking of chopping the banjo fitting off all together, getting 2 barbs to fit exactly onto the new turbo and using some high pressure hoses to seal the coolant into the new barbs.

Will this work?

satanic Grand Master

satanic

Posted
  • Author
Posted

The banjo fitting isn't out though... it's still stuck on the coolant line - it's a one piece banjo + line fitting.

We've just been to Enzed to get some new banjo bolts, they seem to do the trick at the moment (going on a lot easier and not bottoming out on turbo)

We've also got some thicker washers from there, the ones we used last night were wafer thin so that may explain some of the issues.

Couldn't find the hose barb I mentioned before, so I hope this is the solution. Bloody expensive banjo bolts I tell you :(

discopotato03 Grand Master

discopotato03

Posted
Posted

I was once in that situation and the fix was actually very simple . Provided the banjo bolts are too long you can selectively shorten them with a bench grinder so that they clamp the copper washers to the banjo and bearing housing . If you do grind them make sure you clean up the threads before screwing them in .

If you have access to the gas torch heat the copper washers carefully and quench them in cold water , this will soften them if they've been work hardened and help them seal . DO NOT guts the bolts when doing them up , those production banjo's can easily deform and never seal .

Hope this helps cheers A .

I had one worse that that also , had a turbo built from a new bearing housing and one of the bolt holes was not drilled/tapped square to the spot facing - a little late to be finding out .....

satanic Grand Master

satanic

Posted
  • Author
Posted

Well we just fitted one side of the turbo with the new bolts from Enzed coupled with 2 copper washers on each side of the banjo (one large and one small)

Did a trial water into the radiator test and there is NO LEAKING! Thank god for Enzed :blink:

Craved Grand Master

Craved

Posted
Posted
Well we just fitted one side of the turbo with the new bolts from Enzed coupled with 2 copper washers on each side of the banjo (one large and one small)

Did a trial water into the radiator test and there is NO LEAKING!  Thank god for Enzed :O

yes yes <_< go enzed

:lol: ahahha good to hear its fixed up.. when you tuning it?

satanic Grand Master

satanic

Posted
  • Author
Posted

WOOT!!! Car has been finished :O All in time for the Friday night cruise as well :P

Just like to thank everyone, especially Chris and Aaron for the very very good help and support throughout this! Thanks to everyone who threw ideas at me to try out!

WIND UP THE BOOST NOW BIATCH!

Chris; tune will most probably happen tomorrow or next week... maybe a bit too late to get a booking in.

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