Turblown? or something less sinister?

[DiscoClax]

So.... driving home tonight. Turn out of side street, bit of welly to punch it up the hill (steep, 100 zone)... and an odd harsh fast rhythmic clatter suddenly starts from out front somewhere (sounds a bit like a manifold leak, or a very loud tappet - that sort of thing). Get straight off the skinny pedal, wait listen feel, gingerly reapply and a sort of muffled pop followed by a MASSIVE exhaust leak and notable lack of the lazy hand-of-God shove I am so used to. Littlest one in the car with me, have to get home, it's just over the hill and around the corner. So I gingerly limp it up over the hill with it sounding like a chaff-cutter (but a meaty V8 one), coast it down the other side and turn into my home street and gently coax it the last km home.

Obviously down on power. Smell of combusted diesel wafting in. Huge, choofy exhaust leak. And very little flow out the RH tailpipe at idle. Unloaded the sprog at home and had a bit of a look. Can't see anything obvious, but the exhaust leak is somewhere from the RH side of the engine, more towards the rear... probably. Hard to get in there. Plenty loud from over the engine, equally so through the wheel-well. Family duties mean I've now just about got the kids into bed and enough time to pen this and get to bed and not much else as we have guests tonight (of course we do...). So no chance to have a proper look.

Other info:

2008 RRS TDV8 @120k - EGRs and coolers have been completely removed and all openings blanked.

DTCs are:-
P132B (turbo boost control A performance)
plus P0490 and P045C which are occasional, repeating EGR codes I see (the emulators don't seem to stop these completely). Not sure they are overly relevant.

Did NOT (repeat NOT) pump out clouds of smoke out the back. Nothing untoward, no haze even.

So... brains trust. What's the most likely cause? I'm hoping (praying) that one of the EGR bungs has just blown out. If not, I suspect that my wallet is about to cop an absolute flogging.

Edit: Just got the good news my Indie can take a look tomorrow. Just need to limp it around there.

[Graeme]

Hopefully just a major exhaust leak from your EGR blanking plates, eg a lost bolt.

[DiscoClax]

Just heard back from my Indie. Thread pulled and one of the EGR plugs popped out as not held in. MUCH relief :) Quick, easy (cheap) fix. They should all be like that...

[Eevo]

why not tune the EGR out so this doesnt happen again?

[DiscoClax]

why not tune the EGR out so this doesnt happen again?

EGRs both fully removed already and emulators in. This issue was a blanking plug popping out. Not sure a tune will help with that...

However some tweaks to the exhaust system to lower back-pressure would help.... right? :P

[Eevo]

EGRs both fully removed already and emulators in. This issue was a blanking plug popping out. Not sure a tune will help with that...

However some tweaks to the exhaust system to lower back-pressure would help.... right? :P

im assumng it popped out cause of pressure and the EGR';s still being in place.
tuning them out means they never get activated. (not the same as an engine tune)

[DiscoClax]

im assumng it popped out cause of pressure and the EGR';s still being in place.
tuning them out means they never get activated. (not the same as an engine tune)

First thing I did was rip the bloody things out completely. I'm not having that crud pumped through my engine. I want to keep this vehicle for a while. Otherwise I might as well remove the air-filter and stop changing the oil... So mine really can't activate as they are sitting in a cardboard box in my shed... Still considering a tune more to sweeten the engine up a bit and sharpen its response rather than chase big numbers.

[Eevo]

well, what i did, i turned the EGR out, so they never activate and dont pump crud though the engine :)

tune also gave more torque and more response. could almost spin all 4 weeks on the take off (untili put wider tyres on)

[rar110]

Just heard back from my Indie. Thread pulled and one of the EGR plugs popped out as not held in. MUCH relief :) Quick, easy (cheap) fix. They should all be like that...

That’s great news. It would be disappointing if you blew a turbo at 120,000km.

I also have emulators (alternative to EGR delete) and am tempted to do the same (physically remove the valves and EGR cooling system).

[DiscoClax]

Just got the car back and spoke to the mechanic. The EGR pipe that runs from the manifold to the valley broke off at the manifold flange on the RHS. The bracket that supports it screws into a plastic boss and that had pulled through, allowing it to flop around and then fatigue at the base. Those pipes were originally left in as getting in there is a PITA, so were blanked at the other end. Now that pipe has been removed and the manifold blanked. Other side checked and OK. No charge for any of that, which was pretty decent. Otherwise all's well and driving it home it was wonderful again. Just lovely.

Wheel alignment post fitting Compos have given me a it more clearance at the front also (more castor). Now only rubs near full-lock in Access height :)

But I need a new rear door lock actuator :( *sigh*