nevermind!

 

But that would exceed generally accepted limit for a 3/8 bolt in aluminum.....

I'll be visting the local Fastenal tomorrow to stock up on bolts and tap.

 

P38 section shows 50nm for both the GEMS and BOSCH version....

 

IDK what the deal is, but both the RRC and D1 manuals show 38Nm for the intake manifold bolts so that's what I'd go with. Maybe when they printed the D2 manuals they accidently inputed 38ft/lbs which translates to 51Nm, instead of 38Nm(28ft/lbs).
Regardless, I'd use the manual spec for the vehicle I'm working on unless I know it to be incorrect.

 

I think this is how that NASA probe crashed into Mars.

 

I looked in the vehicle manual I was working on, and under SFI (which is what it is) there is nothing on intake manifold, but does say if no torque speced use a stock value for 3/8 bolts. So I made a boo boo finding a nice diagram in the D2 manual.

 

The RAVE that I have states 51 Nm (38 lb.ft.) final torque on the intake manifold bolts in 2 places in the same numbered step in the engine section. Looks like they figured out how to allow higher torque on these bolts with the later engine design. I feel for you on this one. I never would have imagined there would be any difference between the manifold bolt torque on the D1 and the D2.

 

Now, let us think about this - If I drill out and tap for 7/16, which can take the higher torque, which torque should I use - 38 or 51 NM?

And the bolt store and I will decide what to do about the one with a helicoil. Coil is still in there, but just spins at 25 nm. And it is already drilled to same size as you would drill for a 7/16 tap...........

Wonder if a D2 owner should use the higher torque setting?

This is starting to be the mushroom factor.....

 

boy this has become a really drag.
IMHO I would open them all up to 7/16 and use the 38ftpd number.
The one helicoil that spins at 25nm can you back it out? I have seen helicoils used with JB.Weld in the outside while setting, I have also seen helicols stacked.

 

38 shall be used. I hope that darling bolt location under the upper hose fitting will allow the wider bolt head....

The helicoil will be examined more.

BTW, I plan to ammend the first post in the thread with a list of lessons learned for noobies should this thread survive. Lesson one - use a location with a roof.....