I am sofa King, retarded, my AAZ may soon be discarded.

[wisconsinjohnson]

So, I was running 18-20 lbs boost on a k03, without any intercooler, when my turbo decided to seize, big surprise there.  Seeing as I was still maybe a quarter mile from the continental divide, and figuring since it was downhill from there, I decided to try and make it over the pass.  During this successful attempt, I had the great idea to shift into first and stand on it, at speed that produced a wonderful bag of hammers sound, maybe 5-6k rpm?  At this point the turbo started working again, so I just drove home, checked oil, backed the wastegate off to 12lbs, and drove it for a few days.  Today, figuring my expert turning of a couple of 10mm nuts had fixed the problem, I decided to drive up the pass, and the turbine shaft promptly snapped, surprise again.

 

[Gizmoman]

So, I was running 18-20 lbs boost on a k03, without any intercooler, when my turbo decided to seize, big surprise there.  Seeing as I was still maybe a quarter mile from the continental divide, and figuring since it was downhill from there, I decided to try and make it over the pass.  During this successful attempt, I had the great idea to shift into first and stand on it, at speed that produced a wonderful bag of hammers sound, maybe 5-6k rpm?  At this point the turbo started working again, so I just drove home, checked oil, backed the wastegate off to 12lbs, and drove it for a few days.  Today, figuring my expert turning of a couple of 10mm nuts had fixed the problem, I decided to drive up the pass, and the turbine shaft promptly snapped, surprise again.

 

Your title sounds like the lyrics to a country western song - Actually the chorus, the message body is the song.

[wisconsinjohnson]

 
[/quote]
Your title sounds like the lyrics to a country western song - Actually the chorus, the message body is the song.
[/quote]

Yeah, I may have seen  ATHF and convoy a few too many times.  It could be affecting my brain...  I somehow managed to get the posting screen to disallow typing in post body.  Also I think I drove a couple hundred miles without an air filter.  I'm probably retarded.

Well, maybe only partially retarded.  I have installed an intercooler, just haven't plumbed it, and I had acquired a couple of temporary turbos, knowing that turbo failure was imminent.  So  I proceeded to take the cartridge out of the housing, so I could slide in an aeb unit of my old b5, and drive around with no water cooling, most likely.  While taking off the last bolt on housing, I snapped off the head.  Said bolt fell from wrench and directly into intake manifold (carefully blocked off with good intention mixed with a little don't worry about it).   Of course this is a non magnetic bolt, and my spare head confirms there's room for it to fall into cylinder.

So now my dilemma is this.  I pretty much need to pull the head.  I have a one notch gasket installed.  Where hell do I find a one notch gasket?  Which turbo should I install, stock K03 with a ***load of play and a ragged comp wheel, gasser K03 with/without water cooling, or volvo T3 I picked up to put a .36 wheel on? Why shouldn't I just put on the t3  .42 if I'm taking the head off anyway? I have a low mile german? head to port and a 2.5 in? downpipe off saab, so she might spool ok?  Should I just get a two notch and install a block heater?  I still get her started in single digit degrees with low ip pressure (pouring fuel out non-functional cold start).  So I'm not really worried about losing a little compression?  This engine is getting pulled for a re-ring/vnt and put in something awd/4wd or Mk2 in the spring.  I just would like to get it going without waiting 3wks for a hg, and keep it going for a couple more months, with putting much cash in her, can't even afford headstuds right now...

[Gizmoman]

I know what you mean, a one hole is rare and spendy - I bought two for that reason (not selling it either).
I'd slowly rotate and carefully the crank till it stopped, then back it up. Then reach in with a wire with some goo on the end (the grey silicone stuff is quite tacky). Heck, it fell in, you should be able to coax it out.

[745 turbogreasel]

Apply compressed air  through the glow plug hole, and reach down the runner with a  grabby tool, you might win.

[Toby]

I would pull the cam and lay my hands on one of the valve spring compressors that bolt to the cam studs. Put air into the GP hole and then depress the valve as far as it will go and I will bet it will spit the nut back out the intake port. You will get the valve open farther with the spring compressor than the can does at full lift. It would help to keep the piston as close at you can get it to TDC.

[RabbitJockey]

the title reminds me of a few years ago at work.  we had a guy that kept over sleeping.  so we started saying wow you must have been sofa king tired.  he didn't get it and would say "no i was in my lazy boy" haha  he was called the sofa king for a year or so.

[bbob203]

Get a k14 or a t2 much better flow. Mod - burn your money  - can get new t2's.

[wisconsinjohnson]

Good advice guys, but I don't know which port it Plinko'd into, I don't have an air compressor, and I'm working outside over gravel/sand/snow/ice, so if it fell/came out it may just get lost, and I have to it in hand, or head has to come off for confirmation.  Wow, I guess I'm a bit frustrated.  Backed up for a bit and gave it some thought.

Here's the plan;
 
Remove cam cover, and verify which valves are open/how much.

Remove exhaust housing from manifold/remove downpipe.

Support front of engine with jack, remove engine mount and lower front of engine. (It's a b4, so hopefully that will give me more room between engine/raintray)

See if I get lucky and broken bolt is still above valve.

If not:

Off comes head, found one notch hg in Cali can have in hand 3-5 days, 48 bucks delivered.

Giles also responded promptly and said he could order one for me. 

[Gizmoman]

Take it out of the car, hold port-side down, shake vigorously.

Just a thought, you don't need to have it in hand to verify if it's still in there - a gentle of the crank will verify either way.
If you make it to 360 once, try a few more just to me certain.
Also watching the valve stems against the cam to see if one stops short.

Man, what a bummer. I feel for ya.
All I can say is, I'd personally make every effort before pulling the head (unless I wanted to do something else while I was there).

[wisconsinjohnson]

 Victory!!!  Once i had enough room to get my head between the firewall and ports, I was able to spotit, confirmed valve was closed, and started fishing.  It only took about an hour to pull it out with a wire.   As it turns out my gasser aeb turbine didn't even fit in the exhaust housing, and my spare 1Z turbo seems to be full of sand.  So it's t3 time.  I made a plate to mount t3 to k03 manifold, reclocked coldside, and test fitted.  It looks like i need to cut a little tab off the intake, finish final touches on adapter,  use compression fittings to mate oil in lines, rig up adapter to join oil outs, and pull heater hoses and shift cables over a bit,  and then it's just a bit of exhaust.  Should be able to fire her up at least tommorow?9

[wisconsinjohnson]

And believe me, I thought about turning it upside down and shaking it... or at least pulling engine before head, but I'm working with an oem jack over dirt.

[Gizmoman]

Sweet, block off those ports till your ready to put it back together or try to keep your nuts way from them .

[wisconsinjohnson]

According to my roommate, my nuts were more intimately associated with the Ip during this procedure,  but yeah, stuffed w/paper towel.

[CrazyAndy]

Victory!!!  Once i had enough room to get my head between the firewall and ports, I was able to spotit, confirmed valve was closed, and started fishing.  It only took about an hour to pull it out with a wire.   As it turns out my gasser aeb turbine didn't even fit in the exhaust housing, and my spare 1Z turbo seems to be full of sand.  So it's t3 time.  I made a plate to mount t3 to k03 manifold, reclocked coldside, and test fitted.  It looks like i need to cut a little tab off the intake, finish final touches on adapter,  use compression fittings to mate oil in lines, rig up adapter to join oil outs, and pull heater hoses and shift cables over a bit,  and then it's just a bit of exhaust.  Should be able to fire her up at least tommorow?9

I'd just get a T3 manifold.  The k03 turbo flange is a little restrictive when compared to a 8v T3 manifold, stock 1.6TD or otherwise.