Loose Turbo Bolts - growing problem

[DaveMack]

Folks ... it appears I'm the next to be struck down with the bolts loosening on my turbo. I'm taking it into the dealer next week, but in the meantime I'd like to coordinate all the info we have on this strange situation

I've spoken with Guy H today and he said that he's heard of about 12 cars that it has happened to (including his 3 times). There appears to be nothing (yet) that can fix this problem once and for all and he even had it happen when he changed to the KO4.

It's strange because basically, it's the same engine that was in the MKIV GTI and yet it didn't happen with that model and is yet to appear/be publicised in any other VAG model using the 1.8T engine. My apologies, Timbo ... you appear to have covered this well ... it has happened with other 1.8T users.

Symptoms to listen for:
Generally most apparent when cold starting. Engine sounds a bit asthmatic (wheezy) and there may be some metallic jingling (no, I'm not kidding).

When the engine warms up, these sounds may disappear. The symptoms gradually get worse (I don't know what happens if the bolts actually fall out - maybe one or more of you do ).

I rang the service department of the dealer today who said he'd never heard of it (maybe he hasn't ... maybe it's ostrich mentality).

Please let me know if you have had this happen to your Pogo and I'll take all the info to the dealer next week. This may necessitate going as high as VWA or even higher.

Thanks,
Dave

[PoloGTi]

Thats no good at all DaveMack i am sorry to hear it has happened to you aswell. Mine after 10,000ks has not done it again touch wood.
I hope VW look at this issue again and start to think about a long term fix.

[Timbo]

Sorry to hear about that Dave, and I'll be interested if your dealer can even identify the bolts you're talking about!

Unfortunately, dealer service reps never seem to go anywhere near forums, which is kind of strange because I tend to frequent internet sites associated with my work passions (settle -- I know it's an opening for a cheap joke at my expense, but resist the temptation )

As I said in the thread I started, search the 1.8T vortex sub-forum for loose turbo bolts, and you'll have hours of miserable reading.

The cure so far (and I know even Guy won't sign in blood on it) is replacement bolts, the HP replacement gasket, crush washers and some thermo-nuclear Loctite. Any new and better ideas gratefully accepted.

[DaveMack]

Sorry to hear about that Dave, and I'll be interested if your dealer can even identify the bolts you're talking about!

Unfortunately, dealer service reps never seem to go anywhere near forums, which is kind of strange because I tend to frequent internet sites associated with my work passions (settle -- I know it's an opening for a cheap joke at my expense, but resist the temptation )

As I said in the thread I started, search the 1.8T vortex sub-forum for loose turbo bolts, and you'll have hours of miserable reading.

The cure so far (and I know even Guy won't sign in blood on it) is replacement bolts, the HP replacement gasket, crush washers and some thermo-nuclear Loctite. Any new and better ideas gratefully accepted.

Tim, I've got that diagram you provided ... so I'll take that with me. Thankfully it hasn't reached 'tractor' proportions yet and I'll certainly be fitting the new dogbone mount from APR.

You would think that, with the history this engine has, they would have sorted something out by now. Apart from that ... I love the power-train in this thing.

Dave

[Timbo]

You would think that, with the history this engine has, they would have sorted something out by now

A state of denial supports a state of inertia

[99gti]

That's not good to hear mr mack! I hope it all gets sorted quickly for you. Keep us posted. If we need to bring in the heavys just let me know

[Flaps]

Sorry to hear Dave

[SoVeReIgN]

Why is this any different to any other fwd VAG 1.8t?! And theres been millions of them.

Different exhaust manifold?? Different engine mounting?? Exhaust mounting??

[Guy_H]

We just pulled our turbo bolts yesterday (third time )

This time we used new VW stretch bolts, high tensile spring washer, super loctite (Highest rating) and it stayed together for 3 months

The bolts stretch & come loose, the EGT's can hit ~800 - 900 C (even on a stock car) so it just overcomes the material tension of the bolts.

Now I have seen this happen also on a stock Polo GTI with 2000kms on it (the dealer suggested they visit us as they couldnt find the source of the noise).

Now the stock bolts dont have a hardness grading on them - so they may be a little "soft" - so today I will search for some that exceed a 10.90 in tensile strength (like a subframe bolt) - most suspension type bolts are hardness 8.8 or greater.

The factory bolts are marked "SD" which all I can guess is a "stretch" marking - they have no other tensile grading markers at all.

Some aftermarket high flow manifolds come with grade 10.9 for this joint, but I have seen them fail as well.

Now if we can just find someone who can make / supply us an inconel bolt in M10 x 50mm x 1.5 pitch we would be well on the way to having a permanant solution for this

Anyone in the aircraft industry? aircraft often use inconel

http://www.boltdepot.com/fastener-in...ade-Chart.aspx

[Guy_H]

P.S., I'm sure it has happened, but in all my years of owning & working on the other 1.8T's - I have never seen one of these bolts come loose