So we got it done....sort of...
Nearly everything was cake, pulling the fan off, new belt, snout oil, easy-peasy. We cleaned the crap out of everything. All the bearings were good, the snout oil was a nice medium golden color with no junk in it, not bad for 65,000 miles. All the plugs looked evenly worn, blower turned smooth.
We took it nice and easy getting the blower back in place. My wife, who loves to help with this stuff ran and got a tube of anti-seize when I got lazy having forgot to pick it up, insisted I used it on the manifold bolts in addition to the plugs.
All smooth sailing until...
We started working in the bolts evenly, gradually upping the torque on each one. We got to about 19 foot pounds on the 3rd bolt back ( blower discharge side ) from the front and "SNAP"....broken bolt....WTF?
Pulled all the bolts back off, pulled the blower off and took out the busted bolt by hand, good thing for anti-sieze. I called toyota to see what they thought about in getting a new bolts, they would have to order it. So in talking more to them, I decided to drill out the S/C manifold threads in that position since according to the dealer, all they do on the blower side is allow you to pre-set the bolts before you put the blower on., but are not used beyond that, hence the reduced shank bolts.
Got another bolt, went at it again, got the same bolt that I swapped a factory one from another position on, just short of 19 foot pounds, mother effing "SNAP" AGAIN!!!!!
On one hand, I wonder if it is my torque wrench, a range of 25-250 inch pounds, or just about 21 foot pounds max which is what those bolts are supposed to be at. But on the other hand, the other bolts gradually build up resistance until it clicks while the problem bolt position just feels too smooth up to 18-19 foot pounds and then the bolt snaps in half about 3/8 of an inch above the intake manifold......really effed up.
So we bolted up once more, set everything at about 16 pounds and will drive all downhill about 40 miles to the shop tomorrow to find out just what the heck is going on.....
****Update****
Nothing blocking the holes into the manifold, so no hydrolock, Torque wrench is fine, dead on. So I got new bolts from Toyota and carefully went to 18.5 foot pounds with the motor fairly cooled off, maybe 85-90 degrees. I will check the torque on them again in a couple days and see if they held.....maybe bump them up to 19 and change and call it good.
New Walbro 255 got put in, a pretty big difference above 3,500 rpms, AFR's look great and motor sounds very nicely aspirated / mixed.
Thanks for listening ( if you did, LOL! ) and thanks for posting all the info you do.
By the way, the nose drive bolts are to be set at 18 as per PSE. You can use Mobile 1 20-50 in it, don't have to buy the spendy GM stuff. Also, the pins on the rotor gear do go on the opposite side of the rounded finish in the coupling slots near the spring, that way it tensions towards the rounded end. That spring is called a "Tension Isolator"...
Peace,
Dan