PD150 overboost/boost creep/exhaust leak?

[dgjdrummer]

Hey guys,

So basically I'm having a boost issue along with I believe a diesel fumes leak. I have had my standard PD150 pancake pipe on for a couple of months but this started roughly 2 weeks ago. Symptoms are as follows:

- Hissing sound from rear of engine on idle
- Increase in volume of hissing sound relative to boost
- Diesel fume smell from rear of engine (I stuck my head back there to listen to the hissing and could smell the fumes and came away feeling nauseous)
- Overboosting in 3rd (2bar+)
- Boost creep in 4th (hits 1.4bar then creeps to 1.8bar before snapping back to 1.4)


These are recent things I have tried/jobs I have done in that area:

- Mr Muscle turbo clean over a month ago
- New o-rings on red turbo pipe and pancake to IC pipe, and new clips on turbo outlet/IC inlet (yesterday)
- Re-fitted 1.8t pancake pipe with JCS hi-grip clamps (also yesterday)
- All other pipes/clips replaced in the last 2 years


All boost pipes looked ok with no splits in them anywhere, they went back in fine and the new o-rings and clips fit fine as well. As I say these symptoms occurred a couple of weeks ago and are still there now after fitting the new o-rings and 1.8t pancake pipe.

Worth noting is that I dropped one of the manifold to EGR cooler gaskets while doing the Mr Muscle clean and bent the gasket but it went back on fine and I presumed that the gasket would flatten out once compressed. Could this cause an exhaust leak and the symptoms mentioned? I forgot to re-fit the EGR gasket once before but that resulted in limp mode, not what I'm experiencing at the moment.

Anyone any ideas where to go from here before spending out on loads of new gaskets/spending a couple of hours trying to strip everything again?
Would another Mr Muscle clean help anything?

Cheers!

 

[dgjdrummer]

Just to add to this, I noticed if I rev the car up to 3k+ in neutral and let off the accelerator I get a sort of air raid siren sound. This only happens as the revs and turbo speed drops, not on the way up the revs.

Hoping it's not bearing seal failure or a completely knackered turbo

 

[Dan FR]

It sounds very much like an exhaust gas leak, more than likely from the EGR assembly - especially since you've been fiddling

 

[dgjdrummer]

It sounds very much like an exhaust gas leak, more than likely from the EGR assembly - especially since you've been fiddling

Even with the boost leak sound and over-boosting issue?

I'm hoping this is the case as it'll be quite easy to sort with new gaskets from the manifold to EGR. I'll have to take my time re-assembling the pipes this time

 

[rivigo]

It might not only be the gaskets, it could be the metal pipe split that goes from the manifold to the EGR, that's what Mines doing.

Sent from my C6903 using Tapatalk 4

 

[dgjdrummer]

It might not only be the gaskets, it could be the metal pipe split that goes from the manifold to the EGR, that's what Mines doing.

Sent from my C6903 using Tapatalk 4

You'll never guess what it was?

The gaskets were ok, but I have new ones to replace them with which have superceded the old ones. They have a kind of retaining clip on then on either side.

Took the EGR off, loosened TIP to gain access, mani to EGR cooler pipe off and found a black line between one of the concertina bits, wiggled it and hey presto, a split! There's only one on ebay at the moment and it's £20, but that means putting everything back together as normal until it arrives. Otherwise I can just buy a blanking plate and gasket for less than £10, but again it's waiting for it to arrive

Gonna pop round the corner to see if they can do anything with this pipe for the time being, otherwise I'll just have to see how it goes! Anyone got any suggestions or temporary fixes?

 

[cupra.al]

can you not just make your own blanking plates its easy enough to do.

 

[cheshire cat]

can you not just make your own blanking plates its easy enough to do.

+1

 

[dgjdrummer]

I don't have sheet metal lying around or any way to cut it to shape. Got the pipe welded up for the time being, fitted new gaskets and running much better now cheers for your help guys!

 

[cocadave]

Exactly same thing happened to mine, I used an old baking tin that i fabricated (butchered) to fit, been sweet ever since. touches wood