KA-Ts will never be done

[Bbandit]

Well, I finally drove my KA-T tonight.
Ran pretty good until problems showed up.

Can you guys help me with these questions?

1. My ECU was throwing code "34". Which means knock sensor.
The first thing that crossed our minds were that we didnt replace the knock sensor on the blcok from my old 91 KA to my current 95 KA (I have a 95 KA in my S13). Is this a possible problem? or is it just my knock sensor is screwed.?

2. I have a major exhaust leak coming from between the turbine and the flange (T3 super 60, 5 bolt flange). we didnt put any gasket on it because we dont have any.
How do you guys do yours? where can I find this 5 bolt gasket? Im having a hard time finding it.

3 can you guys re check my vacuums?

first set:
Intake Manifold -- divider#1: 1. FPR, 2. another divider -- divider#2: 1. boost gauge, 2. BOV

second set:
Hotpipe niple -- external wastegate

Are we doing this correctly? any suggestions?


Well hopefully I can fix all of these by the end of this week...
Thanks guys.

Here's some shot (taken a couple of hours ago)

http://www.imagestation.com/picture/sraid117/pb5743a9f66748fcaceec991d3f25bb84/f8a135a5.jpg

http://www.imagestation.com/picture/sraid117/p9da87b0a4052113c880f34ee75323fb3/f8a135a7.jpg

[Gladman]

When do you get a knock signal?

If you reset the ecu does it come back on at idle or under load, you might actually be knocking.

On the other hand, if you have a bad enough exhaust leak, it might be triggering the knock sensor... valve tick has been known to screw with knock sensors.

Funny you should mention your 5 bolt flange because i have the exact same problem. I looked through the turbonetics catalog and they list nothing.... i dont think theres supposed to be a gasket there, so if you have a leak its because your 5 bolt flange is warped and you need to have it machined flat. Or just make a gasket out of "mr gasket" sheet.

[mbmbmb23]

I know this sounds kinda jerry-riggish........but for the gasket you cant find.....why not get a 7"x7" peice of whatever those gaskets are made out of......and an exacto knife/tinsnips....and make one. You'd have to take off the housing to make the dye marks on the material...but I think it would work.
It couldnt hurt to try.


-m

[bkfill]

what manifold is that?
and downpipe

[95Blue240sx]

there is no way you are going to seal an exhaust leak with gasket material. you either have to machine down the flange on the downpipe, or on the exhaust housing itself. it is just like if a head is warped, you dont just put a new gasket, that will burn up too, you get it machined.

Edit: seeing your engine makes me want to finish my KA-t.... :smash: im soooo damn lazy and broke. looks good too!

[ISTOTOSAO]

Didn't read replys so if it is said already sorry. if it is the same 5 bolt gasket for a t25 then Wayne at Phase2 http://www.store.yahoo.com/phase2motorsports/oemsr20deto2.html will have it.

[TurboB15sentra]

The knock-sensor code is from a faulty sensor, or it's not plugged in. The knock sensor code that sets the SES light off is only present when one of those two conditions are present. It won't set the light off if the engine is pinging and the sensor is picking it up. It will only back the timing down in that case. However, if the SES light for the knock sensor is illuminated, it will pull the max amount of timing in open loop up to around ~5000rpm. At ~5000rpm, the ECU ignores the knock sensor. So, if the sensor is bad, you should feel a "jump" at around 4500-5K RPM where the timing curve jumps back up.

Travis

[Maeda]

Permatex Black is all I have to say. IM me if you have more trouble. =)

[Gladman]

yeah if you want, you can buy a sheet or stainless and cut your own flange... seen that done as well.

[TBreu007]

The ports on your head didn't change shape, nor did the bolt pattern on the exhaust manifold...why not just use the stock 4 gaskets?

[Bbandit]

The ports on your head didn't change shape, nor did the bolt pattern on the exhaust manifold...why not just use the stock 4 gaskets?

are you talking about the head to exhaust manifold gasket?
I was saying that the leak came from between the turbine discharge and the downpipe flange.

[bkfill]

are you talking about the head to exhaust manifold gasket?
I was saying that the leak came from between the turbine discharge and the downpipe flange.

what turbo and manifold is that?
and downpipe?

[Bbandit]

T3 super 60, .63 turbine A/R
ETD-racing manifold
3 inch custom upper downpipe
3 inch SR lower downpipe

[TBreu007]

are you talking about the head to exhaust manifold gasket?
I was saying that the leak came from between the turbine discharge and the downpipe flange.

Sorry...back to 2nd grade reading class for me.
Can't help with the gasket a whole lot, but I can recommend against trying the gasket material you cut yourself. It's made out of a paper material and will breakdown over time if you try and use it in a hot exhaust environment.

Also, high temp RTV will only work for a couple days before it starts to leak. It works great for patching up a small leak in an exhaust gasket, but won't last long as the only gasket.

Maybe you could try and get some copper shim stock or something and make a gasket out of that.

[bkfill]

blah blah blah bandit can i have your car

[KOUKI KA-T]

No gaskets!!! Seriously don't use them, they just blow out. If you plane all the flanges you will be all set, so find or get a belt sander. I don't use any gaskets or sealant. Just plane all surfaces flat and use a little copper spray. Works fine and you don't have to worry about replacing gaskets later down the road, because no matter what they eventually go..

[SilviaDriver]

blah blah blah bandit can i have your car

post something constructive to help his problem or get ur ass out somewhere else.

hope u get ur problems fixed Rey and build me a kit!!!

[kandyflip445]

http://www.rmoreau.com/mms3500.htm You might try this stuff. Looks ideal for what you need. The contact info is at the bottom of the page.


On another note, would you be willing to give me a ride in it if i went down there? ;)

[kandyflip445]

Or this place.http://www.cogebi.com/htp.htm

[Bbandit]

ahhh thanks guys..
silviadriver.. i'll help you piece a kit whenever I get this ka-t running right.. dont worry

kandyflip: of course man.. just let me know whenever you're down here.. thanks for the links too..

[bkfill]

post something constructive to help his problem or get ur ass out somewhere else.

hope u get ur problems fixed Rey and build me a kit!!!

i didn't even know he had a problem

every1s just fighting about the gasket thing

[CoasTek240]

I know this sounds kinda jerry-riggish........but for the gasket you cant find.....why not get a 7"x7" peice of whatever those gaskets are made out of......and an exacto knife/tinsnips....and make one. You'd have to take off the housing to make the dye marks on the material...but I think it would work.
It couldnt hurt to try.

-m
OR

Or just make a gasket out of "mr gasket" sheet

lol :w00t:

[KOUKI KA-T]

Why does everyone want to use a gasket? They just blow out. If you plane the flange you do not need a gasket, and if you do it right it will not leak, ever! If for some reason you still want to make a gasket you might as well make 10 so you have them handy to replace everytime they blow out, because they will.

[bkfill]

EXACTLY! al they do is fight about this man there will never be a real answer cfause everyone still always jsut complain

[Gladman]

Why does everyone want to use a gasket? They just blow out. If you plane the flange you do not need a gasket, and if you do it right it will not leak, ever! If for some reason you still want to make a gasket you might as well make 10 so you have them handy to replace everytime they blow out, because they will.


Not everyone is willing to "down" their car for a few days so they can drop off their down pipe or manifold to a machine shop.

90% of factory turbo cars use gaskets on all the flanges. Why would you wanna run without one?

[Grandpa]

www.roadraceengineering sells 5-bolt gaskets - metal ones. Go to their DIY section and look under gaskets.

However, dude above is probably correct. Although you didn't post a close-up, it looks like you have a pretty thin 5-bolt flange. I bet the welder didn't bolt it down, and it warped when he (she?) was doing the downpipe. Optimally, plane it down. I'm even skeptical about a gasket fixing your problem.

-john

[Bbandit]

yep, my friend who did the welding didnt bolt it down.. so it is warped.. whenever I took off my downpipe, I can see its leaking from the stock WG hole.
I already purchased a 5 bolt metal gasket for it from roadrace.. but they wont ship next day.. and I just got the gasket this morning...
however, I did make a custom gasket for it and it works..
but now I have a huge leak from my manifold/head... the stock felpro paper gasket couldnt handle the awesome torque that the KA-T has ;)
anyways.. im fixing to get her fixed ASAP.. hopefully it'll run right in a couple of days.
I already have the copper gasket for it too.

[KOUKI KA-T]

Not everyone is willing to "down" their car for a few days so they can drop off their down pipe or manifold to a machine shop.

90% of factory turbo cars use gaskets on all the flanges. Why would you wanna run without one?

Takes me an hour to remove my downpipe and put it back on, tops... and all you need is a belt sander. And as I said before gaskets will need to be replaced. If you plane the flanges a gasket is unnecasary. If there's no gasket then there is no need to replace it in the future and you've now avoided this downtime you dread for the future.

And copper gaskets don't last long either. I'm not trying to be dick or argue with anyone, I'm just posting the best method to avoid replacing gaskets in the future.

[Bbandit]

prolly i should just get it machined.. but i dont have time... i need to be at the drift event this weekend..

anyways, I replaced my bad injector today... Im surprised about what happenned to the old injector though... It MELTED.. I dont know how that happenned...
I was backfiring/misfiring pretty bad last week but Im not sure..
Im hoping to fix all of the leaks tommorrow

[bkfill]

2. I have a major exhaust leak coming from between the turbine and the flange (T3 super 60, 5 bolt flange).

how much did you pay for (T3 super 60, 5 bolt flange)
and where did you get it?