Turbo oil feed return pipe leak

[michael sa]

cant see how that banjo bolt can be undone with everything in situ (turbo/exhuast) its so hidden away and inaccessible to get a spanner or socket bar anywhere near it!

I agree, it's an absolute turd of a spot to get to.
Check out page TC-16 ('turbocharger installation') of the engine manual, it says:

"...
1. Install air inlet manifold to turbocharger...
2. Install exhaust manifold to turbo...
3.Install turbo oil pipe to turbocharger...
4. Install turbocharger and exhaust manifold assembly.
4a. Install 2 new gaskets to turbo oil pipe.
4b. Install a new gasket, the turbocharger and exhaust manifold assembly with the 6 plate washers, 6 new nuts and the 2 bolts. Uniformly tighten the nuts and bolts in several passes. Torque: 52Nm (530 kg-cm, 38 ft-lbs)
4c. Install the union bolt and 2 bolts holding the oil pipe to the cylinder block. Torque: Union bolt: 26Nm (260kgf-cm, 19ft-lbs)
..."

Engine manual is here

So going by that order of things, it is possible. I just need to find a contortionist with a double jointed wrist to get near it...

[stormforce]

i found that using a 3/8 or 5/8 socket set and with a long extension bar i was able to get to it at an angle enough to tighten it enough.It is a pig to actually get the bolt in and grip enough to use the socket on but take your time on it and you'll manage to do it like i did.
Like i said earlier i had never done any work on a surf untill i had to change my turbo at xmas and now i know how to do it i think i could do again easy

[andycook]

i will need to buy some chainmail gloves too!

I am down in Redruth for a friends wedding in the summer, so will drop it off in your drive for repairs!! haahaa

[stormforce]

i will need to buy some chainmail gloves too!

I am down in Redruth for a friends wedding in the summer, so will drop it off in your drive for repairs!! haahaa

i'm 4 mile up the road so if you wanna call by your more than welcome as i will be laid up anyway.I'll pm my no.if you want.If i am well enough we can always have a quick look anyway

[andycook]

sure, but hopefully have it fixed by then
would probably take the Scooby down as more economical for travelling the length of the UK !
had thought of flying to Bristol and hiring a vehicle to drive to cornwall, as have a christening to goto in Bristol on same weekend. but will cost loads and got mountain bikes with us to explore dartmoor

looking forward to seeing cornwall again, did my PhD geology mapping on the Lizard area for 4 yrs

[stormforce]

sure, but hopefully have it fixed by then
would probably take the Scooby down as more economical for travelling the length of the UK !
had thought of flying to Bristol and hiring a vehicle to drive to cornwall, as have a christening to goto in Bristol on same weekend. but will cost loads and got mountain bikes with us to explore dartmoor

looking forward to seeing cornwall again, did my PhD geology mapping on the Lizard area for 4 yrs

that is a lovely area down around there.
Could you not get a flight to Newquay,i don't know if they do go as far up as you are tho

[andycook]

Had an attempt to change this pipe at the weekend,
and gave up as couldn't get anywhere near taking the oil inlet banjo bolt off,
its too inaccesible,

to do it the exhaust downpipe will have to come off and maybe the manifold between downpipe and turbo
I cannot see anyother way, i got a socket onto the bolt, but couldnt turn it

did want to take these off at the weekend as MOT was yesterday - which it PASSED !! - thats the last 3 MOT's in a row passed 1st time - since i have owned the 4runner,

I managed to slacken 2 of the exhaust downpipe nuts, but the 3rd nut is spot welded onto the exhaust flange, and a bolt fitted, so looks like the stud was snapped in the past, and i didnt want to faff with this just beofre MOT,
the bolt head is very rusty and slightly rounded (not my doing! for once), so i maybe have to use one of those grippy sockets i have

i asked garage about doing the work, he reckoned at least 4 hrs, maybe more,
but he didnt want to take my money for replacing such a cheap part really,
he suggested i try again, and bring truck in if i can get the exhaust off and he will oxy the bolt off!

[stormforce]

Had an attempt to change this pipe at the weekend,
and gave up as couldn't get anywhere near taking the oil inlet banjo bolt off,
its too inaccesible,

to do it the exhaust downpipe will have to come off and maybe the manifold between downpipe and turbo
I cannot see anyother way, i got a socket onto the bolt, but couldnt turn it

did want to take these off at the weekend as MOT was yesterday - which it PASSED !! - thats the last 3 MOT's in a row passed 1st time - since i have owned the 4runner,

I managed to slacken 2 of the exhaust downpipe nuts, but the 3rd nut is spot welded onto the exhaust flange, and a bolt fitted, so looks like the stud was snapped in the past, and i didnt want to faff with this just beofre MOT,
the bolt head is very rusty and slightly rounded (not my doing! for once), so i maybe have to use one of those grippy sockets i have

i asked garage about doing the work, he reckoned at least 4 hrs, maybe more,
but he didnt want to take my money for replacing such a cheap part really,
he suggested i try again, and bring truck in if i can get the exhaust off and he will oxy the bolt off!

Andy there are 2 bolts accessible from the top and 1 from underneath on the exhaust

[andycook]

So - when you bolted pipe back on, did you have exhaust downpipe off /removed from the truck? and the elbow bend, between turbo and exhaust?

as think it would be impossible to do without one or both of them off?

hope you are recovering OK

[stormforce]

So - when you bolted pipe back on, did you have exhaust downpipe off /removed from the truck? and the elbow bend, between turbo and exhaust?

as think it would be impossible to do without one or both of them off?

hope you are recovering OK

mine was off as i was doing the turbo.I also took the bracket off that is bolted to the rear of the block to gearbox and to the exhaust to give a bit more play on the exhaust

[andycook]

ahh - I'm not so impressed now! - I thought you had done it with all the bits in place,


makes me feel less of a failure now, and will try again and try not to snap the bolts...

[michael sa]

mine was off as i was doing the turbo.I also took the bracket off that is bolted to the rear of the block to gearbox and to the exhaust to give a bit more play on the exhaust

ahh - I'm not so impressed now! - I thought you had done it with all the bits in place...

I think he's lead us up the garden path andy... I was always sceptical that it could be done without removing the turbo and manifold.
Mine is still leaking, I might get to it over the next few weeks. (note enthusiasm level... ) Luckily I don't drive it far each day and I have no trips planned for a while.
(No road-worthy (MOT) checks over here either...)

[andycook]

5 hrs into the job...

have replaced the pipe now, but need to get exhaust and other brackets back on
took 1.5 hrs alone with hacksaw blade in hand to saw off a bolt on the exhaust downpipe (original stud had been replaced with bolt at some point in history)

managed to do job with only taking downpipe off exhaust , and didnt have to take the turbo/exhaust bend pipe off
but it was still fiddly,
tested and new gaskets not leaking oil
engine and turbo sound great with no exhuast!

reckon a couple hrs to finish off job, replace exhaust and tidy up garage

the turbo/engine support mount had rusted through at one end, maybe thats why pipe leaked, too many bad vibes....
so will replace that

[michael sa]

...the turbo/engine support mount had rusted through at one end, maybe thats why pipe leaked...

Where was your pipe leaking - gasket or crack?
Mine *looks* like the wrong length bolt was used on the turbo support bracket during reassembly after the head was done 2 years ago, I guess I'll find out when I do it. I suspect that movement may have caused my pipe to crack also (at the engine block flange end)
Thanks for the update. It sounds like it was a right bugger of a job

[andycook]

it was leaking about 3cm down from flange, on the main pipe,
cant actually see the split/hole on the pipe now it is off, but oil was only weeping out, so it is probably very small

excluding sawing off that exhaust bolt, i took me 3 1/2 hrs to get old pipe off and new on,
it might be easier after taking the turbo/exhaust outlet bend pipe off
but that itself would involve undoing 4 rusty, hardish to get to nuts! and disturbing the gasket - so i left it on,
but the exhuast downpipe HAS to come off, to make that banjo bolt vaguely accessible!

guess i should order a new support bracket or try and make one if i have any suitable metal around the place

some pics attached