Turbo Installation Problems

[blur:R]

Hi Everyone,

Just wondering if anyone's ever had the following problems fitting a turbo to an RB25DET, and if so, what did you do:

1. When fitting the turbo, being a highflowed standard unit, you've found that the original banjo bolts for one of the water lines, that used to fit perfectly, is now too long and effectively prevents you from screwing them in all the way...

2. When bolting on the dump pipe, the 2 centre bolts (of 6) are IMPOSSIBLE to insert due to the widened neck area of the dump pipe where it connects to the turbo.

Now logically thinking, but not being of sound mechanical background, will simply grinding the banjo bolt a couple of threads shorter effectively fix problem 1? As all i can see is that the bolt is too long, so shortening it seems the most logical action?

As for the second problem...can you leave these 2 bolts unbolted? Or at the very least, screwed in but not completely tightened?

So frustrating having the hardware ready to go but coming across problems like these...

P.S. Have a Fantastic Christmas all... and the enjoy new year celebrations after that.

[dnb]

are you sure the bolts too long?

have you forgotten the washers?

[blur:R]

Both washers are on there... made 100% sure i didn't lose any of those...

I can actually see inside the hole where the bolt inserts a small mark where the end of the bolt made contact with the housing. Not happy bout it, but I didn't even realize the bolt was too long until i got to a point where i thought "stuff it i'll take it off again......"

[Robo's]

1) Did you stretch the water lines? You might have to bend it back.

2) Are you using a new dump? I find with installing an aftermarket dump pipe i have to constantly move the dump so i can thread the bolt in. There is no way the bolt will go on if i tighten all the other bolts first.

[blur:R]

1. The water lines were shifted slightly. Approx 2mm on the banjo with the length problem. I found that after I removed the turbo, and investigating how deep the banjo bolt actually went, that it was actually the length of the banjo bolt (too long) that was preventing it from securing the water line in place.

2. I managed to wiggle the dump enough to get one of the centre bolts on properly. I couldn't tighten it with any tool in my posession, however the centre bolt on the opposite side is making contact with a slight bend in the dump pipe. The bend appears to be from the round pipe being flattened to fit the exhaust side of the turbo. Abit annoying...that's why i'm curious as to whether or not i even need it....

[blind_elk]

It can't be a "standard" unit, otherwise the banjo bolts would still fit. Unfortunately, not the best time of year to be taking it back to the guys who sold it to you and ask for it to be remedied.

With the dump pipe, you will always have this problem because part of the design is to open out that area of the pipe. You could try replacing the bolts with stud / nut combo, but there's still the problem of getting a spanner onto the nuts to tighten them.

[dnb]

i always use a vband.its so easy!

cant you keep the pipe hard out against the head of the bolt while you do it up?

[blur:R]

It can't be a "standard" unit, otherwise the banjo bolts would still fit. Unfortunately, not the best time of year to be taking it back to the guys who sold it to you and ask for it to be remedied.

With the dump pipe, you will always have this problem because part of the design is to open out that area of the pipe. You could try replacing the bolts with stud / nut combo, but there's still the problem of getting a spanner onto the nuts to tighten them.

The exhaust half is not standard anymore. It looks as tho they may have modified it/replaced it during the hi flow process as the oil line that sits on top still fits, but it is not the same as it was before (i took photo's of the entire setup prior to removing the turbo and although all the lines are roughly in the same spot, the connection doesn't look the same). Either way, All bolts except for the water line on the engine side of the turbo fit fine.

mmm... I think i may modify the bolt for the exhaust as well.... because that too is a length issue. I'll take photos nex time so it's easier to picture what's happenin'....

[discopotato03]

Don't be scared to shorten those Turbo water banjo bolts , they can be ground or cut shorter and the thread dressed up to suit . Just dont overtighten them too much and deform the banjo itself .

[blur:R]

Don't be scared to shorten those Turbo water banjo bolts , they can be ground or cut shorter and the thread dressed up to suit . Just dont overtighten them too much and deform the banjo itself .

Good Stuff... All is well now. All the water/oil lines are in and there appear to be no leaks. All that's left now is to keep an eye out on the engine temps (as i think there is still some air in the water system which i need to bleed out)....

Car is running well... doesn't make that whining spool noise that i've become accustomed to..... Boost is heaps laggier, but more solid (if that's the correct description) i'm hoping that it will slowly become more responsive as i break in the turb....

Thanks for everyone's input. I gotta say the 'HOW TO' by JimX contributed HEAPS to getting the old turbo out:

http://www.skylinesaustralia.com/forums/sh...ead.php?t=22118

Fingers crossed that nothing else decides to blow up (metaphorically speaking).....

[BHDave]

Did you get the dump on properly?

Have you considered allen key bolts if not? Just an idea.

[blur:R]

Did you get the dump on properly?

Have you considered allen key bolts if not? Just an idea.

I put on 5 of the 6 bolts tightly.... The bolt in question i did not install...

As for the allen key bolts... I think that might work (as its the head of the bolt that prevents it from being fitted)...I'll pop down to the local auto shop & see if i can find something..

Cheers.