Upgraded turbo; have exhaust leak that I can't find

Hi, All,


A few months ago, I had installed one of the turbo kits with exhaust
manifold. Since the initial start of the engine, have had an exhaust
leak. The smell gets picked up by the fresh air intake for the
cabin/interior.

If you stand in front of the car by 1-2 feet on a calm (windless) day/night, you
can smell exhaust quite strongly.

It's been up on the stands and no telltale signs of exhaust leaks - the usual
soot trail. My installer, no need to mention names or whose turbo/kit it is,
has checked high and low. Found one tiny leak at the down pipe to exhaust
pipe. This was fixed; but, to no avail.

One can't use their nose to find the culprit - gets a tad hot around the engine,
turbo, and exhaust. So, I'm looking for an easy way to spot the leak.

Sorry, suggestions about pouring various and sundry fluids into the intake are
viewed with a certain distrust. My reply would be something akin to
I'll do it after I come over and do it first to your TDI....hey, it's my daily
driver and like most TDI'ers - I love my car.

Yes, a proper downpipe is in the works followed by an exhaust - but,
this is a couple or more months away. Fixing the leak is a must have -
getting rid of the interior exhaust smell is a high priority - not to mention
getting rid of the potential health hazard.

Appreciate the help in advance.

Lon

P.S. Oh yeah, the car goes like stink with the turbo kit...couldn't resist the pun.
It pulls like a Belgian draft horse...strong and all day.

I am betting that the gasket was installed wrong. Its very easy to do ask me how I know. Do you have the sound of an exhaust leak or just the smell.

The gaskets will go on either way. But if they are on wrong you only have about 1/8 in of sealing surface and it will start to leak with in a few days. But its usually loud under the hood.

My crankcase ventilation is vented to atmosphere, and it smells just like an exhaust leak.

KERMA said:

My crankcase ventilation is vented to atmosphere, and it smells just like an exhaust leak.

Click to expand...

Ah so! Charlie, if you would let us know how to reroute this, sounds like
this should fix the problem.

The kit has been rock-solid. The car has made A LOT! of 1,000+ miles
treks since installation without any hiccups...knock on wood (CYA).

Thanks in advance.

If it was an exhaust leak between head and turbo, you would hear it, as a tapping sound and/or whistle. and also see the soot on either the head or header wrap. Sometimes the gasket between the turbo and manifold leaks if it's misaligned or pinched during installation. (I experienced this very problem myself during my recent install on the Evil Beetle- the large mounting bolts grabbed the edge of the bolt holes on the gasket, preventing a good seal, even though they felt like they were torqued, but it was easily visible and audible)

My golf stinks bad when it runs because the CCV blows tons and tons of blowby- that motor is tired and ready for an overhaul after years of abuse as my test bed and racing and dynos and several blown up turbos and overheating from *two* failed water pumps. That's why I first though it had something to do with your CCV.

No visible signs of leakage around the manifold according to
the installer - and he was underneath looking back up.

No CCV smell - which, to me, usually has a trace or more of
that hot oil smell. This is definitely an exhaust smell.

As I mentioned in a PM, the CCV flow is routed through large, heater
hose to the catch can and from there to the OMI. Currently,
"off-road" testing with the OMI capped - no oil haze or accumulation
where the hose exhausts at.

Do have a chirpping sound when boost hits around 20-22 psi. Sounds like
some type of jungle bird. Let off the throttle a bit so that boost
drops below 20-21 and the sound go away. Add a little more boost
so that you hit 20-22 and the sound comes back. Been there
since the install.

We're both kinda dumbfounded on the chirp and the whereabouts
of the exhaust leak.

I thought the chirp might be the CCV puck. Was poking about
and removed the puck and found out that the grommet it mounts
into atop the cam/valve cover was torn about half-way through.
Replaced it and the sound of the chirp has certainly decreased,
but is still there - just not as noticeable.

Appreciate the suggestions and help.

It's F1 time at Indy - leave tomorrow, Thursday, for home
and practice/qualifying/race!!

The chirpping sound is like a v-belt making noise except it
only occures at 20-22+PSI. Runs fine in spite of exhaust leak
and stinkin' up the interior and my lungs.

Thoughts?

Lon

is it a steady sound, or a pulsing sound? Like a steady whistle, or a chirp chirp chirp

At what rpm is this 20 psi happening?

If you hear a chirp or what sounds like a fluttering noise that happens rapidly, that may be surge.

KERMA said:

is it a steady sound, or a pulsing sound? Like a steady whistle, or a chirp chirp chirp

At what rpm is this 20 psi happening?

Click to expand...

Charlie,


Don't have the rpm's - never looked; but I would say it's rpm independent as
it happens at 20-22PSI regardless of speed. But, I'll take a look next time.

The sound is a steady chirp-chirp-chirp.....until I back off the throttle and hence,
decrease the boost.

Thanks for the help.

ldm

Is it possible you have exhaust leaking out past an injector?

If it was leaking around an injector, I should see signs of
soot and possibly fuel...clean as can be.

Will be getting suspension and brakes done this weekend - so,
will have opportunity to peek and poke about.

It's a long shot...and on a different engine..but it may be worth a shot. I have a chirping exactly as you describe on my 2004 PD Jetta. It started immediately after the dealer performed the egr recall. It only "chirps" during acceleration or deceleration when passing through a certain rpm range. I took it back and of course got the "everything checks out OK " report, but that's another thread by itself. I've yet to tear it down myself, but I know there is a tiny leak somewhere in the egr system. Whether it is a misplaced gasket, cracked pipe, or loose bolt I'm not sure yet. If I find anything more than a improperly installed gasket the whole thing is coming out and I'll block it all off.

Anyway, just a thought to take a look at the egr system (or plates covering the remains thereof.....)

KERMA said:

is it a steady sound, or a pulsing sound? Like a steady whistle, or a chirp chirp chirp

At what rpm is this 20 psi happening?

Click to expand...

Charlie,


Got some rpm numbers. I could only get 3rd, 4th, and 5th gear
rpm's - trying to do this in Beltway traffic is a pain. Also, I was
reading from the 'ant-sized' tach in the NB.

I get/hear the chirping sound at 2500 rpm in 3,4,5 gear. I can get
a slightly reduced in volume chirp at higher rpm's in 4th and 5th - but
didn't have chance to get a good sampling.

About egr being a possible culprit - OOPS! I think the egr fell off
during my "off-roading"...care-of Diesel Geek and his race pipe.

The 2500 rpm (could be 23XX or 24XX rpm - couldn't read the
Scan Gauge which is mounted low in car); so, it was close to 2500
if not 2500 via the tach reading.

Charlie: saw your downpipe - for me and being in SALT belt
during winters - gotta have good gauge, stainless throughout.


Thanks to all for the input. Darn, no F1 or LeMans race this weekend!
Maybe there'll be a Rolex DP...gotta check the schedule. Now, if
FOX would create an international "speed" channel: DTM, F1, WRC,
Australian V8 SuperCar, AMLS, etc....maybe I'll win the Lotto too!


Cheers,

Lon

BUMP.

Having same issue VNT 17 installed and now getting a chirp, like a bird at 1800 to 25-2700RPM.

N8SPN said:

BUMP.

Having same issue VNT 17 installed and now getting a chirp, like a bird at 1800 to 25-2700RPM.

Click to expand...

You're bumping a 6 year old thread? Come on man, stop being lazy and make a new thread.

When I put my 17/22 in the studs came out to the exhaust from the turbo, put slightly larger ones in no more leaks!