Loud rattle-type noise under boost (manifold bolts) - Solved!

kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
You'll never get to that 3rd bolt without taking the TIP off and the heat sheild at the back. Got this down to 15mins now

What do you have to remove exactly to tighten them all up? My rattling is on its way back and I want to replace bolts+gasket to get this sorted once and for all!

Can I just remove the top part of the tip? And is the heatsheild that flat piece of metal?

I need to get that black pipe and metal bit in front of it out the way:
E21-10007.png
 
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Ric 2001

Need an ID-ten-T form
Sorry Kriso not been on here in a while... Basically you need to remove the heat sheild, yeh the flat metal at the back. No need to remove the 90 degree pipe or the heat sheild wrap at all.

No need to undo anything in that picture.

This is held on by 1 nut on either side.

So I remove the top of the tip but find the tip is still in the way so I completley remove this, undo the nuts at the back of the heat sheild and then you can get to the bolts. I purchased grade 4.4 I think stainless steel bolts, new gasket, and spider (shake proof) washers.

(Touch wood) This has lasted so far.
 
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kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
Ok cheers. And the heatsheild is number 12 on this pic?

Edit: Oh yea..you just edited to say that :) Still, the pic is good

E21-10002.png
 

olliep

Wants a mk2 GTI
Oct 3, 2005
709
1
Winchester
Just had some good news for once... after repeatedly having issues with these bolts i've just recieved a call from my dealer volenteering to replace the turbo under warranty. the thought being that because it keeps having new bolts and tightening etc etc the thread will be nackered. whoop!
 

kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
Nice one, Ollie :)

No warranty on mine anymore so tomorrow I'm going to order:

3x 058 145 540 (bolts)
1x 06A 253 039 E (gasket)

and hope this fixes it!
 

kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
The rattle has been back recently so today I took another look at my bolts. One of them was about 6-7mm loose so I must have been losing some boost. I replace the 2 I could get to with new bolts and Nordlock washers and tightened them right up. Turbo seems to spool up quicker now and I'm back to full power :D

In theory, the Nordlock washers won't ever come loose, but I'll wait and see. I'll have to do the 3rd bolt sometime too.

Here's a pic of the new and old bolts and washers:

DSCN3807.jpg
 

kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
Not sure, it might take some time for them to start coming loose as they are lower mileage :shrug:
 

kriso

_______ C U P R A _______
Jan 29, 2007
2,325
4
Brighton
1 month later and the bolts are still as tight as I did them up when fitting the new bolts and washers (f**king tight!).

So looks like Nord-Lock washers are the way forward for anyone else having this problem :D
 
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