1.8T Turbo gasket/seal failure -- common problem? long term fix?

[Beetsport]

We have had problems early on with the turbo mounting bolts coming loose, or rather stretching when heated up due to over-torquing.

Using the original bolts and true clean surfaces are key. Proper torque is the most important. The bolts they must have high temp anti-seize on them prior to installing. The threads in the turbo must be cleaned from debris so they can be torqued correctly. We run the bolts into the turbo several times prior to installing them to the manifold.

Make sure the turbo lower mounting bracket is there also. A missing bracket will cause strain on the bolts when they are red hot.

We have tried different bolts with the tab lock but found the original bolts with proper torque work the best.

My Syncro is put under a lot of stress as many of your's are also. Our Wunder Bread race Vanagon has original bolts and we all know the stress it's under.. They will last if set up correctly initially.


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'90 Syncro Westy 1.8T with 180hp 174 torque, CA safe!
http://H2oVanagon.com
http://www.thesamba.com/vw/forum/viewtopic.php?t=217285

[Zeitgeist 13]

I didn't know there was such a thing.

We needs more deets
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[riceye]

24hrs of Lemons! Hahahaha!

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'87 Westy Weekender - daily driver on salt-free roads

There's gonna be some changes made.

“I find that things usually go well right up until the moment they don't.” - Ahwahnee

"Quality isn't method. It's the goal toward which the method is aimed." - Socrates, later quoted by R.M. Pirsig

[Waldi]

This screws are not just simple 8.8 or 10.9 screws.
They are heat resistant.

Maybe you can see the differance in the price.
JX original turbo screws.

https://www.ebay.de/itm/VW-Bus-T2-T3-Turboladersch...rmvSB=true

[theadventureneverends]

I had the conversion done summer of 2011 at 139k now 152k. Shipped it south and my wife and I flew down and drove it back. Heard the first sound of a possible very faint exhaust leak just upon leaving Wavelengths surf shop in Morro Bay with a concrete wall next to us and windows down on our drive North.

I think I have always had a slight exhaust leak just enough to kinda know its there when driving with windows down and a barrier next to the vehicle.

A couple years after conversion had a massive exhaust leak and limped into a campground during a road trip late in the evening. We went immediately to bed. The next morning on our way back from the bathroom my wife picks up something from the ground near rear of westy and asks me what it is. I say wow that is an exhaust gasket and why we are here. One bolt was completely missing and the other two were backed out allowing the gasket to be blown out.

Stephan immediately mailed me 3 new bolts and gasket. I used antiseize and believe I torqued to spec. Every now and then could still hear a slight leak for years, it started getting worse lately and bothering me. Maybe two months ago found a large crack in the exhaust manifold, was bummed but stoked to have finally found the leak.

Had to separate the turbo to replace the manifold. Did not appear to have any leak at that gasket and all 3 bolts were still snug with probably 10k on them. Since I had to separate the turbo from manifold I replaced the good gasket and what appeared to be good bolts with new oem, torqued to spec the best I could with antiseize. I replaced all 3 gaskets manifold/turbo/turbo exhaust, replaced manifold, replaced a few other studs and nuts since I was in there.

Started up and idled perfectly sounded GREAT. Took for test drive and want to say was the quietest had ever been but there still may have been a VERY slight leak. The westy is not our daily driver.

Just back from a 2k road trip. Definitely have an annoying exhaust leak. Runs perfectly but we had the windows down alot and I was in the fast lane on I5 from Central Oregon to Gig Harbor Washington and the constant sound of marbles in a tin can drove me nuts.

I have not started checking for where the leak is yet but might today after washing it. Sure hoping to find it at the turbo to exhaust as that's super easy not looking forward to finding the leak at manifold or turbo gasket.

So from my experience the OEM bolts and gasket held fine for 10k and might have indefinitely being torqued to 27ftlbs and antiseize had I not had to separate to replace manifold.

Will report back with findings on new leak. I so hope it is the easy gasket. That turbo gasket is not in the easiest place to reach any suggestions on how to verify an exhaust leak location if one can't feel or see it?

Stephan has been great and always answered any question I have had even 7 years after conversion! I have high regard for him and his shop and I love having the 1.8T!

[danfromsyr]

I'm not saying this is your issue
but I had marbles in a tin can and was a wastegate flapper that wasn't shutting completely and was rattling on the pivot arm.

https://www.google.com/search?q=loose+wastegate+flapper
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[Paulbeard]

[katzenjammer]

Thanks for all the responses.

First report from the shop after day 1 (voicemail -- couldn't ask questions) is that my turbo is cracked and must be replaced. $850 from VW, eBay versions of unknown quality available for much less. I'm not inclined to go the eBay route, but I'm open to suggestions.

And while I'm here, is there any reason to think that installing vent scoops would be helpful?

http://www.t3technique.com/accessories/body-accessories,-stickers,-etc/bullihutzen-(vent-scoops)/

Dan
Dan
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1990 Westy Multivan, Auto (3.08 R&P) 1.8T by SAH

[theadventureneverends]

Curious if you are able to post a picture of your cracked turbo.

I noticed a crack in mine. I could not see that the crack went all the way through and I did not replace.

Any thoughts on the crack in my turbo?

[Waldi]