Guide: Helicoil the Oil to Turbo Feed in Situ

[Giblets]

I had to helicoil to the oil feed -> turbo banjo in the engine block today so I thought I'd do a Guide. I had to make some modifications to some tools to be able to do it in situ. You'll also need to be very careful to keep any swarf from going into the engine .

Here's the how to:

You need to drill out the existing threads, but you can't get a drill in the engine bay...so.... get a 31/64" drill bit and grind a hex head on the shaft so you can fit a spanner on it. Hmmm nice bodge



It took about 20 mins to work the drill into the block. Put some grease on the drill to get as much of the swarf to stick. Have a hoover attachment on it and regularly clear the swarf from the hole.

Next, you can't use the standard tap wrench cos there's no space, so get a 8mm socket and bodge that onto the end of the tap It's actually a good fit... (You can probably buy a tool specifically for this)



Again use the hoover loads and grease the tap....
Job done. Took about an hour in all



Edited to say: This is a bit of a bodge. If you want precision engineering, take the engine out and pay $$$$ for someone to do it properly.... or buy a longer banjo bolt and hope it bites on whatever theads you have left.

Edited again to say: Make sure the hole is perfectly straight or you'll have problems sealing the banjo. Mine was slightly off

[Mark]

Excellent consider it included in the useful threads

[p.nicholas]

or get a longer bolt made up perhaps

[elvis]

I had to helicoil three cam bracket holes after i sheared the bolts

It took me about two days to finish because i was trying to drill the holes as straight as possable not easy!

[kuddy]

Very useful pics & guide

[crouchy]

looks very useful as i have snapped the banjo bolt it the oil feed on the TURBO itself. its in a garage atm tho as i am not confident at drilling into my blower

[Mark]

looks very useful as i have snapped the banjo bolt it the oil feed on the TURBO itself. its in a garage atm tho as i am not confident at drilling into my blower

You dont have to dril into it, you just unscrew the bit left in the turbo

Never over tighten Banjos as the sheer really easily

[crouchy]

You dont have to dril into it, you just unscrew the bit left in the turbo

Never over tighten Banjos as the sheer really easily

i wish it was that easy, its not got much to grab, ive just taken it to a garage to get out for me. im not very confident when it comes to poking about with the turbo

just hoping its ok for japfest or ill cry.

[Chris]

i wish it was that easy, its not got much to grab, ive just taken it to a garage to get out for me. im not very confident when it comes to poking about with the turbo

just hoping its ok for japfest or ill cry.

You could have just knocked a torx or spline bit into the centre and spun it out

[Mark]

You could have just knocked a torx or spline bit into the centre and spun it out

Exactly

thats all the garage will do and probably charge you a mint for it

[crouchy]

Exactly

thats all the garage will do and probably charge you a mint for it

i no but i dont have any of these tools and 3days before japfest i havent got the time to learn how to do it.

i want to go on the stand so it wa s just easier and convinient at the time.

its done now so i can out it back together tonight

[FIGJAM]

Nice work, not to be a complete cock but you do know that not a heli coil, its a re tap