stripped threads on EGT sensor bung.

[kbjy11]

Hi Guys,

I have an issus where the threads where the passenger side EGT sensors go in are stripped.

Won't take a plug.

I have 2 questions...

1) Where is this bung located in respect to the turbo? are there metal shavings by my compressor wheel right now?

2) is it safe to weld the hole shut? assuming a welder can get in there?

[Capt. Obvious]

Huh huh, you said "bung".

[highPSI-S4]

I believe the EGT is mounted on the exhaust manifold area, I have no clue about getting metal shavings in the comp side on the turbo.

[infinkc]

It's on the exhaust manifold, but before the compressor, so you can get shavings in the hot side but they will just go out the exhaust where the intake side you will have issues

[S4 MIKE]

Yes the EGT is in the manifold right above the turbo. I would replace the manifold. And yes metal shavings could get to the compressor wheel. It's your call.

[slowz32]

Time for a motor pull and mani R&R

[kbjy11]

no way i'm pulling the engine, lol.

You think i can just tap it, and little mr. k03 will be okay with the shavings from the tap?

I could also zap with the weld and plug it, and delete the EGTs sensors...

Hmmm.. oh the decisions... what do ya'll think?

[B6T]

You could probably get a right angle drill in there so you can drill it out and tap it with a heli-coil, if you want to retain your passenger side EGT. Otherwise you could try threading a tapered plug in there and tightening it down. I'm not sure if any of the NPT sizes will fit.

Like someone else mentioned, you'll have to pull the engine to replace the manifold if all else fails.

And the metal chips shouldn't hurt... chances are your K03s are going to die soon anyway, it's unlikely a few chips blowing through the turbine at idle speed will do any significant damage.

[judeisnotobscur]

I was gonna suggest that you tap and plug the holes earlier but that would start the whole egt's are needed/ no they aren't debate again.
just grease your tap really good to collect all the metal.

[ECS Tuning-Audi]

And yes metal shavings could get to the compressor wheel.

This is incorrect. It would be the turbine wheel not the compressor wheel. The compressor wheel is the cold side of the turbo that pushes air to the intake manifold. The turbine wheel is what the exhaust gas spins to drive the compressor wheel. There's no way possible for anything pushed out the exhaust to get sucked back into the engine.

That being said I would be worried that metal particles could travel through the blades on the turbine wheel and possibly seize it up. The clearances are very tight and it wouldn't take much for a fragment of steel to get lodged between the blades and the turbine housing.

Jason

[Don Supreme]

Turbine wheel as Jason said... Either way you don't want those shavings getting on either wheels. They are only ko3s, so who cares ?

Time for an upgrade perhaps?

[fshowcars]

cast manifold? use a magnet...

how did it happen? shouldn't be real big metal shavings (even for turbo turbine wheel-eating sakes) unless you ran a huge tap through there or literally sheered off teh threads?

i'd sweep with a magnet and pull vacuum with a shop vac / vac pump... cross fingers, tap and plug, then drill out a new egt bung? or run a tap through the existing, clean up the threads and go at it???

[ECS Tuning-Audi]

cast manifold? use a magnet...

how did it happen? shouldn't be real big metal shavings (even for turbo turbine wheel-eating sakes) unless you ran a huge tap through there or literally sheered off teh threads?

i'd sweep with a magnet and pull vacuum with a shop vac / vac pump... cross fingers, tap and plug, then drill out a new egt bung? or run a tap through the existing, clean up the threads and go at it???

To do that I think you would have to pull the engine. At that point you're better off removing the turbo from the manifold and re-taping the manifold while its out of the car. Then blow it out with compressed air and reinstall.

Seams to be the safest way to keep anything happening to the turbo.

Jason

[fshowcars]

I was being completely ignorant (or just ignoring reality) with the limited working area.

you can sweep with a magnet and plug while in the car right?

[ECS Tuning-Audi]

I was being completely ignorant (or just ignoring reality) with the limited working area.

you can sweep with a magnet and plug while in the car right?

It might be possible but its even more possible that because of the limited amount of working area lots of cussing would take place. Haha.

Even more so if you wreck a turbo because something happened to go through and ruin it.

I think everyone who owns an S4 should know how to pull their motor. There's so many things that require it to be pulled to work on. The satisfaction of saving yourself thousands of dollars alone is enough to want to make me at least attempt it.

Jason

[DiscoPotato]

Metal bits & turbo do not mix. Period.

[littleredwagen]

EGT is not in the manifold. It is in the turbo hotside after the turbine wheel.

[DanS4]

Hi Guys,

I have an issus where the threads where the passenger side EGT sensors go in are stripped.

Won't take a plug.

I have 2 questions...

1) Where is this bung located in respect to the turbo? are there metal shavings by my compressor wheel right now?

2) is it safe to weld the hole shut? assuming a welder can get in there?

1) in the exhaust manifold
2) Sure, but how bad is it striped? can you get any threads?


My question- How did you strip the passenger side? You can almost put your face right at the bolt. The EGT has some space left over after it is fully threaded into the bung.

[judeisnotobscur]

EGT is not in the manifold. It is in the turbo hotside after the turbine wheel.

nope, it's in the manifold... unless u are being sarcastic, lol

[DanS4]

nope, it's in the manifold... unless u are being sarcastic, lol

I just went and looked it is definitely in the exhaust manifold, at the flange to the turbo.

[Capt. Obvious]

If I was in your position and wanted to do everything possible to keep from having to yank the engine, I'd probably just ghetto rig it.

I'd cover the threads of the EGT with a bunch of high-temp thread lock goo and then just cross-thread the bastard in there while crossing my fingers it seals well enough to not get an exhaust leak. Either that, or I'd use some JB weld instead of the thread lock and worry about fixing it the right way when/if you ever pull the engine for other reasons.

[morris400]

Same thing happen to me on the passenger sida manifold. I used a high heat adhesive and stuck the egt back in. Has worked fine for me no issues. Dont use jb weld it will not hold. When i used jb weld it only held for a cupple days then the egt swnsor blew out. Cant remember what i used but i know it was a high heat adhesive.

[B6T]

It's so easy to say "oh yeah pull the engine and do it" when you're not the one actually doing the work. Haha!

[littleredwagen]

unless u are being sarcastic, lol

bingo

[kbjy11]

hey guys, thanks for the replies..

the thread got stripped during removal.. either someone else stripped it before and put it back.. or the threads were so seized, that during removal, the threads got stripped.

either way.. the shop re-tapped it upon my request...

now... i hear a high pitched noise when on full boost :( ... i am unsure if it is the dreaded dentist drill sound or just the sounds of spooling turbos... (went from oem precats + cats to nothing)....

does the dentist drill noise usually happen at all boost levels? ie.. 5 psi vs 15..etc..

[zillarob]

If you just put on new downpipes you will definitely hear the turbos more.

[fshowcars]

hey guys, thanks for the replies..

the thread got stripped during removal.. either someone else stripped it before and put it back.. or the threads were so seized, that during removal, the threads got stripped.

either way.. the shop re-tapped it upon my request...

now... i hear a high pitched noise when on full boost :( ... i am unsure if it is the dreaded dentist drill sound or just the sounds of spooling turbos... (went from oem precats + cats to nothing)....

does the dentist drill noise usually happen at all boost levels? ie.. 5 psi vs 15..etc..

dentist will be at full boost but also partial boost and loud at cold start... i bet you are hearing your downpipes... don't sweat it.