Author Topic: Need some help! Throttle body elbow Dejon kit replacement (Read 10414 times)

sunnygator · « **on:** June 13, 2009, 10:44:07 AM »

Ok, I got all the right parts and t-bolts clamps from our friend dave. That part all looks right.

1st I did get the old one off.....and the top clamp did seem pretty loose!

But I'm having some trouble getting the new one on. Probably, I need to remove or loosen some of the stuff "in the way"

Anyway I was wondering if someone could describe the stuff they needed to remove to wriggle the dejon elbow kit into place. So far I loosened one mount on the stock pipe - had to do that to wriggle the old one off and out. I'm trying to put one clamp tight/one clamp loose on the "engine" end of the dejon elbow to get it into place, and put the longer silicon end onto the stock Al pipe with both clamps loose on the stock aluminum pipe. But I'm having trouble getting the silicon to slide onto the stock Al pipe far enough to wriggle the dejon elbow into place....

So anyway wandeering if I'm struggling 'cause I'm not taking enough stuff out of the way, or if I should just wriggle a bit more.

Thanks,

sunnygator

Go-N Def · « **Reply #1 on:** June 13, 2009, 10:47:48 AM »

It's basically a big PITA to get that thing on. I did loosen the mount nearest the intercooler though. That at least helped with the lower part of the elbow. You're on the right track...

Have you tried cursing at it? That helped me tremendously!!!!

sunnygator · « **Reply #2 on:** June 13, 2009, 10:59:59 AM »

Quote from: Go-N Def on June 13, 2009, 10:47:48 AM

It's basically a big PITA to get that thing on. I did loosen the mount nearest the intercooler though. That at least helped with the lower part of the elbow. You're on the right track...

Have you tried cursing at it? That helped me tremendously!!!!

Yep, tried that! And I disconnected the little connector to the skinny pipe that Joe describes in his post.....thanks for the support. I think I'm getting closer....

You still deployed?

sunnygator

sunnygator · « **Reply #3 on:** June 13, 2009, 12:03:58 PM »

well I'm stuck here :

Can't seem to get the dejon to fit into the silicon or get the other end onto the engine....

gonna have to take a break

sunnygator

sunnygator · « **Reply #4 on:** June 13, 2009, 12:44:32 PM »

Well I think I finally got it......give me a few minutes to stop sweating and then I think I'll get 'er done.

Had to loosen the brackets some more by the intercooler, remove the TMAP wiring....now it is in place gotta slide the silcon tubing a bit.

sunnygator

sunnygator · « **Reply #5 on:** June 13, 2009, 01:13:31 PM »

Well I'm still just 95% done, and still sweatin'

I need to slide the silicon about another 1/4 inch off of the Al tube from the intercooler, and another 1/4 inch onto the Dejon elbow, there is not enough tube on the elbow for proper clamping....but it really doesn't want to move..........any tips on getting a silicon coupler to budge?

sunnygator

Sol Asylum · « **Reply #6 on:** June 13, 2009, 03:36:44 PM »

Try lubing it, if it was still apart I would say use some hand soap on the inside of the silicone tube either that or silicone grease. Problem with the grease is that it might allow the tube to slide apart even after you clamp it so a water based substance would probably be better. KY maybe. I would try to work something between the aluminum and the silicone tube with a thin screw driver or such. Good luck

Deep-GXP · « **Reply #7 on:** June 13, 2009, 03:59:32 PM »

That Silicone seems so short. An inch longer and evenly cut and im sure it would help you tons.

elff · « **Reply #8 on:** June 13, 2009, 05:44:58 PM »

If you completely remove the driver side IC Pipe
Put the elbow on, then put the IC Pipe back on, it's really easy doing the elbow and actually takes less time.

With the IC pipe on the car, even when loose, it's a Pita

sunnygator · « **Reply #9 on:** June 13, 2009, 08:04:08 PM »

Well I thought I had it done, even drove it around a bit. Then on my second trip into town, boost went to zero, and the dejon elbow had slipped out of the coupler on the engine.....and if you'd asked me before hand I thought that was the "best" connection.

So tomorrow, I either have to put the stock elbow back on, or try once again.....I do think I will remove the driver's side intercooler piping....but I have a question:

I can disconnect the TMAP sensor clip no problem, but what about the tube above it? I removed the baby spring clamp, what else do I have to do?

sunnygator

LiquidPT · « **Reply #10 on:** June 13, 2009, 08:15:10 PM »

Quote from: Sol Asylum on June 13, 2009, 03:36:44 PM

Try lubing it, if it was still apart I would say use some hand soap on the inside of the silicone tube either that or silicone grease. Problem with the grease is that it might allow the tube to slide apart even after you clamp it so a water based substance would probably be better. KY maybe. I would try to work something between the aluminum and the silicone tube with a thin screw driver or such. Good luck

Strangely enough, I use quick detailer as a lube when putting on silicone connectors. It comes in a spray bottle, provides just enough lubrication, and dries without a residue.

sunnygator · « **Reply #11 on:** June 14, 2009, 12:05:21 PM »

Well it's all working right now, 100% done.

As before, I removed the electrical connector from the skinny Al tube.

This time I did completely remove the driver's side Aluminum pipe from the intercooler. Had to disconnect the TMAP sensor cable and the tube (a vacuum hose I think?) from this first. After removing the spring clamp on the tube, it will just slide up an off, but it does take some twisting and pulling. Removed both bracket mounts completely for this IC pipe, both the pipe from the bracket, and removed the brackets too for more wriggle room. Getting the IC aluminum pipe to slide off the hose up front was a bit of a pain, i used a little bit of poorboy's dressing as a lube, and did use a flathead screwdriver to help work it off.

Once the driver's side Aluminum IC pipe competely out of the way (which only took about 20 min) it was pretty easy to get the dejon elbow and couplers on. I put the couplers onto the dejon elbow first, and made sure to measure the gap all around, then tightened the Tbolts. One coupler is only 2", so I put it on leaving 1" extended. The other is 3", so i put it on leaving 2" extended, as measured from the inside of the coupler. Be sure to think about how the T-bolts will face, there is not much room. Then I attached it to the engine end, and tightened the "top" Tbolt. Look carefully all around the top to make sure it is flush and the top tbolt is correctly positioned.

Then, with the last tbolt slid up on the Al intercooler pipe, I wiped a little poorboys dressing on the inside on the coupler as a lubricant, and the pushed the aluminum intercooler pipe into the other coupler. Then I wiped a little dressing on the other end of the IC pipe and pushed it down into the hose up front. Then I just had to reconnect the TMAP sensor, vacuum tube and the other electrical connector, make sure all the Tbolts were tight. Then I reconnected the brackets. The one up front was no problem, but the one near the middle of the Al IC pipe no longer aligns properly. I think I read something about this on the dejon site, too. So for this bracket I put it back in place and tied it to the pipe instead of bolting it. I will fix that another day.

Moral of the story - if anyone is trying to put on the dejon elbow, take off the entire driver's side intercooler pipe first! It was way easier than all the sweatin' and cussin' I did yesterday!

I did take some picts, I might update this later. Gotta run now

And thanks elff and LiquidPT, your advice was grade a #1!

sunnygator

GregGXP · « **Reply #12 on:** June 15, 2009, 07:37:07 AM »

Believe it or not hairspray (pump type) works great also. When wet it gives good lubrication and then dries tacky.

Quote from: LiquidPT on June 13, 2009, 08:15:10 PM

Strangely enough, I use quick detailer as a lube when putting on silicone connectors. It comes in a spray bottle, provides just enough lubrication, and dries without a residue.

Arabas · « **Reply #13 on:** August 27, 2009, 08:19:41 AM »

i just received the Dejon throttle body elbow. it has one clamp already fitted on and Dave in a note stronlgy advises to use it and not replace it with a T-Bolt.
is this the way you all did it or did you use the T-Bolt?
i will go for installation tommorow and i wanted to check.

elff · « **Reply #14 on:** August 27, 2009, 10:05:47 AM »

I used t-bolt clamps on both the upper and lower connection for the throttle body elbow.
Was the clamp that is already fitted on, a T-Bolt clamp?

Here is a pic of my installation[Note all 4 clamps are T-bolt Clamps.

Arabas · « **Reply #15 on:** August 27, 2009, 10:37:31 AM »

there was a clamp already fitted (not T-Bolt)
below is what i have.
i was thinking that dave can not be wrong, on the other hand if i use the simple clamp instead of the T-bolt, why change in the first place?

pls advise elff

http://img39.imageshack.us/img39/9091/p1020747.jpg

DeepBlueGXP · « **Reply #16 on:** August 27, 2009, 10:58:17 AM »

Once you get a tune, the old clamps do not hold well enough to prevent the hose from coming off under the higher boost pressures.

Arabas · « **Reply #17 on:** August 27, 2009, 11:05:14 AM »

Noted DeepBlueGXP!
so, your suggestion is to use ALL four T-Bolts that Dave sent me and GET RID OF the simple clamp that is already fitted on the tube i received from Dejon

(Pls check foto of what i have received)

http://img39.imageshack.us/img39/9091/p1020747.jpg

rich71 · « **Reply #18 on:** August 27, 2009, 11:07:53 AM »

i can't see the pictures at work, but worm clamps on the throttle body are junk junk junk. t-bolts are the only thing that should be used. Most get away with the factory worm clamps that connect the intercooler. they seem to stay sealed for some reason.... but other than that, it t-bolts or boost leak.

elff · « **Reply #19 on:** August 27, 2009, 11:12:45 AM »

IMHO - I'd replace that one.

That's the style of clamp that always seems to fail. Looks like you have enough T-Bolt clamps to eliminate it.

DeepBlueGXP · « **Reply #20 on:** August 27, 2009, 11:14:38 AM »

Like everyone else says, that clamp is a worm gear and replace it.

Kelu · « **Reply #21 on:** August 27, 2009, 11:23:05 AM »

I don't see a reason why to keep the worm clamp.

Arabas · « **Reply #22 on:** August 27, 2009, 11:39:19 AM »

Crystal clear !
will replace that with a T-Bolt that was provided!!!
Thx a lot for your replies!!!

Arabas · « **Reply #23 on:** August 28, 2009, 08:40:43 AM »

Dejon throttle body elbow Dejon Kit replaced in my Opel GT. thk God i didn t try it myself... it seemed like a PITA as i was watching the mechanic replacing it...
all 4 T-Bolts were used.

thx for all your help!

elff · « **Reply #24 on:** August 28, 2009, 08:55:51 AM »

It's really not that bad. The trick is removing the driver side intercooler pipe first
then it is a piece of cake

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Author Topic: Need some help! Throttle body elbow Dejon kit replacement (Read 10414 times)