on the turbo housing theres an extra coolant passage that goes to intake manifold that u dont use on a n/a. right underneath the outside air passages(not sure of correct term). how can i block those so they wont leak coolant on a 89 n/a.

 

you can do one of 2 things, 1 being tapping and threading it and using a pipe plug to seal it or 2, you can pick up some o-rings that fit the housings and some silicone to the gasket around the coolant passages and just seal it up to the intake manifold.

 

jb weld my friend

 

what are the rectangular holes under the air passages of a s5 for??

 

You beat me to it. Karack's suggestions are prob better, though.

 

i've tried the o-ring and sealant thing and it will seep out coolant because it is only pressing against a gasket and not metal... frankenstein engine. you're either going to need to plug it up or if you have the engine apart turbo housings are worth a decent amount so you can sell them and get some nice na housings.

 

so what is jb weld and how does it work??

 

how about u sell me the housings and find buy some off ebay (there are some on there going for $175.00 i beleive)

 

jb weld is goop that turns into a really strong compound. comes in two tubes, mix 'em together and turns into this gray stuff that's hard as hell. sold everywhere: lowes home depot wal mart autozone oreilly's...it's like 4 dollars for the little pack, but autozone sells this huge pack for 20 that i recommend....you'll use it more than you'd like to admit.

 

I've had no problem from just getting the correct sized rubber O-ring for the indentation on the housing, then using RTV black silicone on the LIM. The O-rings are key. Without them it will eventually blow through and you'll have a BIG problem with leaking, but not only that, the leaking coolant will seep into the intake ports causing all sorts of issues, lol.

 

I think that Mazdatrix sells a freeze plug for this...

http://www.mazdatrix.com/FAQ/6PEXH.HTM

Part Number: EO/9325

 

actually i think he is referring to the EGR passage, is this an n/a engine that you used a turbo middle iron on?

 

Judge Ito uses $0.25.

 

i guess it would work, but i just don't feel like it's a long term solution because the s4 gaskets are paper/rubber/whatever and can soak up coolant and even on a s5 i wouldn't feel good about it simply because the o-ring isn't directly between two pieces of metal.

 

O-rings have been used successfully for years, even in the oem configuration. When I rebuilt my 12a, I used 22 mm freeze plugs, with a dollop of J-B Weld. Either will work well, the freeze plugs are permanant.