alextstone Posted October 3, 2019 Report Share Posted October 3, 2019 This CO leak was hard to find but so obvious once I did. The intercooler duct has a bonded cabin heat chamber in the back side. A previous repair was made and the wall of the chamber was deteriorated at the border of the repair. I repaired it again with Kevlar cloth and high heat silicone. CO levels are near zero now. Alex Sent from my Pixel 3 XL using Tapatalk 3 Quote Link to comment Share on other sites More sharing options...
carusoam Posted October 3, 2019 Report Share Posted October 3, 2019 nice find Alex! Thanks for sharing the details... Best regards, -a- Quote Link to comment Share on other sites More sharing options...
ArtVandelay Posted October 3, 2019 Report Share Posted October 3, 2019 I would not call that a repair, I call that a patch. I would expect new metal to be welded to be a repair. Is that even legal?Tom 1 Quote Link to comment Share on other sites More sharing options...
alextstone Posted October 3, 2019 Author Report Share Posted October 3, 2019 I would not call that a repair, I call that a patch. I would expect new metal to be welded to be a repair. Is that even legal?Tom Tom, the part is fiberglass, the patch is Kevlar with a metal skin. There is no way to weld it. Yes it's legal because it's signed off by an AI. Sent from my Pixel 3 XL using Tapatalk Quote Link to comment Share on other sites More sharing options...
ArtVandelay Posted October 3, 2019 Report Share Posted October 3, 2019 Tom, the part is fiberglass, the patch is Kevlar with a metal skin. There is no way to weld it. Yes it's legal because it's signed off by an AI. Exhaust temperature is ~1500°, that’s averaging done by the probe, and high temperature silicone is only good to 500° for prolonged exposure? And according to one site: “Kevlar fiber can withstand temperatures up to 800 degrees F “ Are you sure it won’t be exposed to these temperatures? Quote Link to comment Share on other sites More sharing options...
alextstone Posted October 3, 2019 Author Report Share Posted October 3, 2019 Thanks for your concern, Tom. Here is description on the Kevlar Heat Shield: I'll keep a close eye on it. 1 Quote Link to comment Share on other sites More sharing options...
kortopates Posted October 3, 2019 Report Share Posted October 3, 2019 48 minutes ago, ArtVandelay said: Exhaust temperature is ~1500°, that’s averaging done by the probe, and high temperature silicone is only good to 500° for prolonged exposure? And according to one site: “Kevlar fiber can withstand temperatures up to 800 degrees F “ Are you sure it won’t be exposed to these temperatures? Alex refers to Intercooler ducting. That's not exhaust, but the output of the turbo compressor going into intercooler for cooling before the compressed is routed into the cylinders. As such it shouldn't get much above 300F (if that high) on the input side and less by 60-80F on the output side. If it was exhaust that would be a different story. 1 Quote Link to comment Share on other sites More sharing options...
ArtVandelay Posted October 3, 2019 Report Share Posted October 3, 2019 Alex refers to Intercooler ducting. That's not exhaust, but the output of the turbo compressor going into intercooler for cooling before the compressed is routed into the cylinders. As such it shouldn't get much above 300F (if that high) on the input side and less by 60-80F on the output side. If it was exhaust that would be a different story. Ahhh, I see now, thx. I’m obviously not a turbo guy.Tom 1 Quote Link to comment Share on other sites More sharing options...
Awful_Charlie Posted October 4, 2019 Report Share Posted October 4, 2019 22 hours ago, kortopates said: Alex refers to Intercooler ducting. That's not exhaust, but the output of the turbo compressor going into intercooler for cooling before the compressed is routed into the cylinders. As such it shouldn't get much above 300F (if that high) on the input side and less by 60-80F on the output side. If it was exhaust that would be a different story. It's not even that! That moulding on one side takes the external air and pushes it through the intercooler, on the heat shield side takes the heated air from the exhaust muff to the blending valve for distribution to the defroster and heater. The heat shield is protecting the moulding from the exhaust (#5 to #3 to #1) which is only 1/2" away I'm not doubting that this has fixed your CO reading, but curious as to where the CO was coming from to get in there? 2 Quote Link to comment Share on other sites More sharing options...
carusoam Posted October 4, 2019 Report Share Posted October 4, 2019 Interesting point AC! See if Alex has his finger on the right details... Something has gotten lost in the explanation... Does exhaust ever cross through the turbos halves? Along the shared drive shaft? Best regards, -a- 1 Quote Link to comment Share on other sites More sharing options...
alextstone Posted October 5, 2019 Author Report Share Posted October 5, 2019 4 hours ago, Awful_Charlie said: It's not even that! That moulding on one side takes the external air and pushes it through the intercooler, on the heat shield side takes the heated air from the exhaust muff to the blending valve for distribution to the defroster and heater. The heat shield is protecting the moulding from the exhaust (#5 to #3 to #1) which is only 1/2" away I'm not doubting that this has fixed your CO reading, but curious as to where the CO was coming from to get in there? Yes, spot on @Awful_Charlie! I was going to explain but you beat me to it. I am still trying to find the source of the CO but given that the entire exhaust was just dropped to install two cylinders and a new starter, I suppose we are back at square one....The exhaust system was inspected AGAIN while off the engine. 1 Quote Link to comment Share on other sites More sharing options...
alextstone Posted October 5, 2019 Author Report Share Posted October 5, 2019 Here's a photo of the part in place so it will be more clear as to why heat shielding is importantSent from my Pixel 3 XL using Tapatalk 1 Quote Link to comment Share on other sites More sharing options...
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