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  1. #61
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    Exhaust manifold gasket?

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  2. #62
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    Probably about the only thing that's left....
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  3. #63
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    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...

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    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...
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  6. #65
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    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.
    Last edited by Dangerous Dave; Monday 25th May 2020 at 21:36.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  7. #66
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    Quote Originally Posted by Dangerous Dave View Post
    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.
    What he said......and....

    Have you checked/replaced the Oil filler cap seal and the dipstick seal?
    2014 V60 Polestar 6spd Auto :: Polestar map peak boost 17.4psi :: IPD 3" DP + 150cel :: Polestar 2.5" exhaust :: Paddle Shift Geartronic :: Black glass :: Maxton Splitter :: K+N Filter :: IPD Aluminium Top engine mount :: Brembo 6 pots :: 20" Polestar rims :: Brembo 371mm floating discs :: Sensus RTi + DAB + BT + WIFi :: D3S XENARC 6000k Active bending headlights

  8. #67
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    You got any further with it?
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  9. #68
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    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.
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  11. #69
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    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......
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  12. #70
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    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.

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  13. #71
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    Quote Originally Posted by MoleT-5R View Post
    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
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  14. #72
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    Exhaust housing from the turbo. Little crack internally but nothing apparent on the outside.
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  15. #73
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    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)
    Last edited by Dangerous Dave; Monday 8th March 2021 at 21:54.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  16. #74
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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....
    62' V60 D3 R Design
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  17. #75
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    Looks like your old one had some porting done on the collector
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  18. #76
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    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.
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  19. #77
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    Part no 1270537 which isn't the stock T5 part
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  20. #78
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    Interesting, I've not seen that one before.

    I've only seen examples of the three below
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  21. #79
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    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.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  22. #80
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    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.
    Last edited by Timo.; Saturday 13th March 2021 at 16:23.
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