Exhaust manifold and turbo removal

Just as an update as far as I'm concerned, having had my van in for a once over at an independent garage it seems that my old skool crappy manifold is in fact in primo condition! This has finally brought a smile to my face!

However, as people correctly pointed out the puff of black smoke generated by maually closing the EGR valve (which I had) does indeed indicate an exhaust manifold related problem, but luckily for me it turned out just to be the gasket which has been blowing heavily and has deposited a whole lot of soot back there around cylinders 1 and 2 apparently. The new gasket arrives tomorrow along with one also for the turbo which had to be removed during the process.

A knock on of all this is that I am no longer in dire need of the PPtuning SS manifold (due around January time I am led to believe), however, I can imagine still being tempted once it does arrive along with their decat setup etc.

Cheers







Edited by Kitawagon - 06 Nov 10 at 07:36

Dave, is there any word on this PPT manifold?

I read this on another forum regarding the PPT replacement manifolds:

Phoned them also- they havnt got any ready until mid/late Jan. Bloke i spoke to sounds very knowledgable. He also said that he can make one in stainless if that is what you really want, but there is really no need + mild is more suited to the job.

 

 

I am envious of you for getting past the exhaust!

Hi Folks, I have successfully done my turbo op, finished it on christmas eve but haven't had the time to put together write up and pics. sorry.
The manifold did weld with a mig, it does look like the sort of material that doesn't weld easily but it welded nice.
On the face of the manifold there is a web between pot 3 and 4 like a brace directly behind the EGR transfer pipe mount. I cut a piece out of mine about 10mm wide and guess what the deformation of the manifold went! I don't know why but it did. there was that much tension on this that when the hacksaw went through the other side it gripped the blade so tight it snapped and I had to pull the manifold in a vice to release the blade! I also noticed that the gasket manifold and head align very poorly so i chopped the gasket across  the bridging gap so it allowed the gasket to line up better. The process of refitting the manifold and turbo is so much easier than taking it all apart for the first time so don't panic.
I have also had deep conversations about my rebuilding of Turbo and had a lot of help from a firm up North and I feel this is worth noting. All the components of the turbo can be got hold of including the actuator for the VGVs. They are easy to strip and rebuild. Here comes the JayLow its a BIG BUT..... you are goint to get stinking black doing these jobs! One of the things that I found out is unless you take the charge air pipes out and they're full of oil,( a bits ok)  or the blades are running on the case don't take it apart!
Since I have done it I reconnected my EGR valve as I think the increased combustion chamber temp increased the warpage of the manifold the crack got a lot worse very quick as well!
When you do any of this be very wary of dropping crap onto the lower turbo mount as this is the oil feed for the turbo and also a direct access to the sump! dont drop any nuts down there!

Make sure that when you assemble the whole shooting match you leave the fresh air inlet pipe for the turbo off and get someone to help you with the next bit. If you leave the inlet off the turbo you can see the compressor wheel and the nut that holds it all together. If you hold this firmly while your assistant turns the ignition the van will start if you hold the nut you will stop the turbo spinning. The reason you do this is simple. The oil pressure from the engine is feeding the turbo passages and effectively bleeding it all through. Let her run for about a minute and it will be purged, then let go of the wheel nut and away she will spin. You will feel resistance while you do this so don't let your mate rev it as you will get a load of red come out of the exhaust. (blood and finger ends!) after they've been through the entire engine system!

Hopefully I will finish my write up and find a way of getting the pics small enough to upload! it will be quite a boring read but helpful i hope.

Jason Statham wrote: Hopefully I will finish my write up and find a way of getting the pics small enough to upload! it will be quite a boring read but helpful i hope.

Hi Guys, I managed to get the manifold and turbo off the van this morning.  

Edited by maderdog_1024 - 05 Jan 11 at 23:51

Hey guys,

Yeah, mine is pretty sooty.... Don't even think about looking at your pollen filter

Hello all..