So I was trying to install a block off plate on the ACV and the two of the bolts I was using broke off at the head. Woops. I then decided to use a helicoil to replace them, but with the one the bottom right I accidentally drilled through into the ACV cavity (the part behind the check valve).

I used a vacuum cleaner and some hose and I think I got all the big ones, but some small ones (dust-sized) are probably stuck against all the dirt and oil inside the cavity. Does this cavity actually lead into the engine? Or is it the one leading to either the catalytic converter air pipe or the air pump?

If I pull the manifold, do I really need to replace the metal gasket?

When I get the block off valve on, will using RTV on the bolt be enough to seal the helicoils?

 

Definitely pull the manifold to be safe, it's not worth the risk. You can usually reuse the metal gaskets with success unless they are really old and appear to be flaking.

Helicoils are just to have a solid mount, not for sealing. If you use rtv on the BOP that will be enough.

 

Honestly. Should be fine. The ACV controls air from the air pump to either the exhaust ports or the cat. If the ACV is no longer used, it's not like it's gonna hurt anything. The shavings from drilling are insignificant enough to damage anything in the turbine of the turbos worst case they vibrate into the exhaust port.

Matt

 

Yep, that area doesn't go into the intake of the engine. May want to blow it out with compressed air too. I wouldn't lose too much sleep over it, that system is a dead system if you're blocking it off.

Dale

 

Well, I don't want to try to use any compressed air or fluids since that might cause them to go into the exhaust port (I think its connected to the air pump and the exhaust ports?). OTOH, if the engine is running there is basically constant positive pressure pushing anything out past the turbo (which would probably be fine so long as its not running at full speed).

OTOH, would the ACV cavity have a lot of positive pressure (boost or exhaust pulses)? I might have to go back and make a blockoff plate out of something thicker.

 

FWIW, I don't think that part is exposed to the actual intake at all.

You sure I wouldn't have to use an o-ring on the bolt or something? Or RTV on the bolt head side.

 

....The exhaust ports would be bad. Actually, how would the intake manifold be connected to the exhaust ports? The little square port below the two oblong ports? I've forgotten how all that works. Or is that for EGR?

 

Straight from the FSM page F-115:

The secondary air injection helps to clean the exhaust gas by introducing fresh air into the exhaust port or the three-way catalyst in relation to the during condition. The PCME controls the secondary air by actuating the solenoids valves (secondary air switching, secondary air bypass, relief 2, port air bypass, split air bypass) and the air pump relay. The system consists of an air control valve (ACV), three way solenoid valves, air pump relay and powertrain control module.

If you blocked it off, it'll be fine. Even if you didn't, the shavings from drilling out should be insignificant after you vacuum/blow them out.


Matt

 

Gah.... The helicoils didn't work (bolt wouldn't thread on one, the other one just pulled out) so I'm gonna just use some Quiksteel and try to thread it for M6 bolts in the original location of the bolt holes.

 

not to hijack the thread, but when you install the blockoff plate, do you need do use the little disk/check valve and gasket, or can you just RTV the entire thing up?

 

You don't need it but I would just put it in there so you don't loose it, if you ever decided to restore the emissions system.