Matt Lane

Had my SAI ports cleaned pre-emptively, they were surprisingly unobstructed at 42K miles. Some solvent from above and brake cable from below, and we're in business.

Noticed that the SAI "manifold" below the check valve has a few cast ports that are plugged with what appear to be push-in metal caps. Anyways, one of mine is rusted out - see the first pic. It should look like the one in the second pic.

Any one deal with this before? My thought is to try to pull out the compromised plug, and try to tap in a new one. Will this work? Technique?

Would love any suggestions on a suitable replacement (plug size, sourcing). I assume that the original caps are not available for purchase? How creative do you have to get?

Thanks in advance for any tips from the SAI Army!



Best,

Matt

swmic

Matt,

Sorry, I don't know where to get a replacement plug but someone posted about the same problem a couple of weeks ago. Seems sort of like a common problem. I'd do a quick search.

Matt Lane

Thanks - found it!

Funny, after reading hundreds and hundreds (!) of SAI posts over the years, they all seem to blend in. You become an SAI "expert" until such time as you have to deal with it, at which point everything is new again...

PM sent to Andreas.

And still open to creative suggestions for a plug solution!

Best,

Matt

earossi

Looks like a potential application for JB Weld or RTV. You need to simply plug the area. Not high pressure or temperature. But, with the opening to atmosphere, you will probably see back flow from the exhause valves which could lead to plugging of the small diameter ports. To attemp a patch, be certain to clean the area extrememly well first.

bobt993

No, to JB Weld or RTV. The exhaust is hot enough and pressure is such that would be a bad idea. You can buy plugs from Porsche that are service parts for the case when you clean the oil passages in the case. You can also mill your own plug and remove the old one. The replacements are solid now instead of the cap look. Next option is to buy an SAI valve from someone not using it. Heck I have two sets.

AOW162435

Matt,
My SAI manifold was removed at around 40,000 miles and is operating-room clean. As soon as I find it, I'll dispatch it to you.

JM993

JB Weld is so strong it can be used to repair engine blocks. In fact, I wouldn't be afraid to use it on an exhaust manifold. Should work fine on an SAI valve.

Matt Lane

That, friends, is the Rennlist way!

I will figure out a plug for mine and put it aside for later or to pass along and pay forward.

Best,

Matt

NC TRACKRAT

How about a metric freeze plug?

MDamen

I used JB weld on mine. I don't think it gets that hot back there. Metric freeze plugs are hard to come by. I believe a 9/16 is very close.

Silver993

I went through this last weekend.

Here's what my manifold looked like before repair:


I tried to find a similar sized freeze plug at local hardware and autoparts stores without success. I found several plug candidates in my garage and pockets:


A US dime seems to cover the hole well, but I decided to use a modified screw:


and here is how it looked after it was JB Welded in place.


No CEL this week!

Let me know if you have any questions as this is all still fresh in my mind.

AOW162435

Matt,
I shipped the manifold today.

Please accept my apologies - it is very clean, but not 'operating-room' clean as previously mentioned. That said, the plugs seem to be in excellent shape, with nary a hint of corrosion.


Andreas

PNogC2S

I thought someone on the board had blown out their plug during an attempted pressure flush and found a freeze plug that worked.

Sorry to criticize, but that fix with the screw head looks a little "ghetto" to me. If no freeze plugs fit, I'd go with an aluminum plug made to order on a lathe.

Slow Guy

That's what I was thinking.

skl2

I had the same issue and have a thread on here about it. I used JB Weld and it's solved.