Exhaust manifold gasket?
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Exhaust manifold gasket?
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Probably about the only thing that's left....
I think the issue could be the homemade RIP kit, it's not one continous piece of pipe over the engine length, the gap between the two joined metal sections could be acting a little like a reed on an instrument. The joins would be my next investigation area or removing it completely...
I've put the original pipework on just this week.
I've done it previously to test that same theory.
Still did it.
Really need to have it on a rolling road to try and find the area the noise is coming from. Fat chance of one of them round my way...
I forgot about one thing. The brake servo.
The hose comes off the inlet manifold the goes under the airbox through a short plastic pipe and then along to the elbow on the brake servo. I think the elbow contains a non return valve so the servo does not get pressurised under boost (there should be a non return valve somewhere in that line).
Maybe worth check the pipe / plastic pipe / joints for cracks (or blocking it off at the manifold to test for the howl, though obviously be careful of braking as it won't be assisted).
It's quite a big pipe too.
You got any further with it?
Na, too busy working and looking after the kids to have touched it. It's got a coolant leak on the tiny pipe at the back of the head. Need to get some new pipe. Even sent Robert DIY (off YouTube) an email. Got a reply suggesting the turbo was maybe on its way out but nothing else.
Attachment 32990Attachment 32989
Finally took the challenge head on.... Clearly the end cylinder has been leaking. Oddly enough the first bolt I tried removing on the exhaust manifold was loose......
Glad you've possibly found the issues cause, but just a thought that if that is the original 850r manifold, I would seriously consider swapping it for the Japanifold or S60R type exhaust manifold, as the collector imho is very restrictive and some good gains can be had for what can be very little expense, if you can find one going cheap, I paid about £30-35 for a Japanifold and £50 for my S60R manifold.
I HOPE this is the issue..... I actually took it all apart to check there were no cracks in either it, or the turbo exhaust housing.....
I am on with the japanifold as we speak. It won't go back together till I have one as there is no way I'm going through that hassle again.
The turbo has whined (not loudly) since I rebuilt it.... Can't decide whether to buy the 2nd hand 850R turbo that's on ebay or buy a brand new CHRA
Attachment 32991Attachment 32992Attachment 32993
Exhaust housing from the turbo. Little crack internally but nothing apparent on the outside.
Not seen a crack there before, they usually go by the wastegate port.
And loose manifold bolts are normal, I had more than one loose when I first took mine apart many years ago.
You can also get the a piece exhaust manifold gasket for a Focus ST engine, saves trying to put those 5 gaskets on and hoping they stay in place lol (think I had to trim the end on the one I fitted to my engine though due to an extra stud on the focus)
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Managed to get a "japanifold" which came today. Looks in good nick.... 850R in picture to compare.
New CHRA ready to fit into Turbo.
New gaskets all round, including the one piece (needs trimmed yet).
Hope to get it fitted over the next few days....
Looks like your old one had some porting done on the collector
I wondered that myself but when I looked for other specific 850r exhaust manifolds it appears that is how they were... I understand they were a bit better than the standard T5. You can certainly see the Japanifold helps even more.
Part no 1270537 which isn't the stock T5 part
Interesting, I've not seen that one before.
I've only seen examples of the three below
http://i.imgur.com/BqpFGWp.jpg
That's the first I've seen like that, must have had a light tickle at some point in it's past neither of my R's have had anything other than the standard manifold that is on the left of Dave's picture, though now one sports a ported Japanifold and the other a ported S60R item so much less restrictive than the standard job.
Exhaust manifold gasket trimmed.
Exhaust manifold fitted.
Wastgate manifold fitted with gasket between exhaust and manifold.
Turbo refitted with new CHRA.
New o ring and gasket for oil turbo return pipe fitted.
What a morning....
No more progress till Monday due to work commitments.
New copper washers fitted to all banjo bolts.