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Yesterday I had planned on bolting my newly rebuilt and upgraded TD05 to the exhaust manifold, then the whole thing onto the engine. Volvo green book says the bolts can be reused if they are 89mm(3.50)or less. Mine measured 86.3(3.40).
So I have the whole thing in the vise, new locking plates installed, and I start all 4 bolts. As I start to loosely tighten them down, I realize that with the rearward bolts I've run out of threads/thread relief area on the wastegate
housing of the turbo. And I still have 2-3 threads exposed beyond the locking plate! So there is no way it can go together as is! As you may or may not recall the 2 rear threads on the wastegate housing allow only a few threads to go through the flange and into the pockets created for excess threads before they run into the casting itself. I had also replaced the cracked old manifold
with a used one. Thickness of the new one from wastegate housing mating surface to locking plate surface is 2.780, old one is 2.810. So this accounts to .030,
but I still need at least .150 more! How did this ever stay together before?
(I will now try to bolt the turbo assy. to the old manifold). When I seperated the turbo form the old manifold before sending it out, all 4 bolts were not very tight. The turbo and manifold had never been off the car. So my options:
1. Buy 2 new bolts(or 4), but if the new ones are any longer than about 3.2 long
then I've solved nothing. 2. Machine/die grind out deeper reliefs for excess threads, 3. Shim the bolts from backside to use up some length with hardened washers under the locking plates (just an idea, not a very good one).
Has anyone else ever run across this? Any and all comments and suggestions are welcome. And thanks to all for past help. Owning a Volvo without a site like this would be very difficult.
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