New turbos with body on

**BobD** · 3rd November 2016, 03:05 PM

My car is currently at Rovertech getting new turbos and an exhaust whistle when cold fixed. They have found that it is easy to get at the turbos once the EGR is removed, so we are removing the whole EGR and associated cooler on each bank and fitting an emulator instead, rather than taking the body off. I should add that the original plan was to take the body off (which they had done many times before) but the mechanics talked to Triumph Rover Spares who advised them that they now just remove the EGR equipment to access the turbos.

The turbos have been removed and the exhaust whistle was found to be warped manifolds and a broken stud on the passenger side. The manifolds are off and getting machined and just waiting for the turbos to come from QLD, thanks to a helpful post on here re a good value Australian source for D4 Garret turbos.

Both turbos had damaged turbines, like some foreign object had come through the inlet tract. They were both working OK, but making a fire siren sound. No idea what could have damaged them at this stage or when it happened. Perhaps there was enough wear to hit the housing although they seemed pretty solid when I had a play with them.

Its been an expensive year or so with lots of wear items replaced such as lower control arms, shocks on all four corners plus inlet manifolds, air con compressor, transfer case and other things that I can't remember at the moment,as well as the turbos. The next thing will likely be the transmission although there are no issues yet.

My car is set up for touring and pre scratched, so I don't want a new one yet! I will keep fixing it to ensure that it is as reliable as possible. I am also replacing the alternator while in the area, although mine has been perfect so far.

If we weren't towing and doing remote trips we wouldn't have bothered with the transfer case (minor play in the input shaft bearings), turbos or exhaust manifold leak and probably left the air con compressor being slow to start and not quite at peak efficiency as well. I definitely wouldn't have done the alternator.

**Graeme** · 3rd November 2016, 03:49 PM

Not good that it's needing all this money spent but no sense taking a vehicle to less-travelled areas that isn't in top condition.

So the emulator development is still moving forwards? I've been trying to get in touch with Gally about mine.

**BobD** · 3rd November 2016, 04:39 PM

Yeah, its a bit of a shame that so much needs doing. However, it has been towing around 2.2t all over Australia since I have had it and the previous owner also set it up for towing so goodness knows what he towed and where! Also lots of hard off road in hot weather.

It is still the best country and rough road tourer available, other than a Vogue, so I just grin and bear it for the incredible comfort and performance. As I have said before it is now retired from every day driving and I'm taking delivery of a new Discovery Sport in about 2 weeks for that purpose to replace a Skoda Yeti. The D4 has done nothing but touring and towing over the last 2 years and needs to be in top condition as you said, Graeme.

I am told there is an emulator but haven't checked it myself. If not, they will have to put the EGR back in I guess.

**justinc** · 3rd November 2016, 05:02 PM

These can be switched off electronically and removed.

Jc

**BobD** · 3rd November 2016, 05:13 PM

Thanks Justin.

**LandyAndy** · 3rd November 2016, 10:10 PM

Originally Posted by Graeme

Not good that it's needing all this money spent but no sense taking a vehicle to less-travelled areas that isn't in top condition.

So the emulator development is still moving forwards? I've been trying to get in touch with Gally about mine.

I was in at Rovertech a month ago.Kevin said Gally had finally cracked the atom with the issues on those Emulators you guys bought.
Hopefully he gets back to you.
Bob,you probably have your toy at one of the best repairers in Australia,Kevin is a good man to have on your team.
Andrew

**disco4now** · 14th November 2016, 09:22 AM

Originally Posted by BobD

My car is currently at Rovertech ..... an exhaust whistle when cold fixed.
....... the exhaust whistle was found to be warped manifolds and a broken stud on the passenger side.

Hi Bob,

I am interested in the symptoms of the exhaust whistle.
I have a whistle/locust/cicada noise when decelerating or no power on. Especially down hill overrun. At first I though it was idler pulley/belt related but its not there. It is worse when cold. It goes away if accelerating.

It this anything like you saw.

Regards
Gerry

**BobD** · 14th November 2016, 10:56 AM

No, mine was different. It was a loud screeching sound (when the windows were down) when you rev the engine, even when there was no load. It went away as the exhaust manifold warmed up but as soon as you stopped the engine it would return at the next start until the manifold warmed up again. You couldn't hear it with the windows up though.

**disco4now** · 14th November 2016, 04:23 PM

Thanks Bob,

The symptoms I described were how it started about six months ago. Last service they did not have time to find it, but said it was not the pulleys/belts.
They don't think its a turbo. I am due for a service so will get them to look further this time, as is now a bit louder and also happens as you describe with a slight rev of the engine when cold. I can hear it with the windows up for first minute or so .

I think something similar to to what you have found is likely.

Thanks for the reply.
Gerry

**BobD** · 14th November 2016, 05:29 PM

The noise on mine was the leaking left hand manifold to head seal. According to Kevin the manifold has quite a cantilever at the front (or back, not sure which) with no studs due to the turbo positioning and mine broke the only stud that was close enough to hold it together due to a warp in the cast iron.

It took them half a day to get the stainless stud out of the alloy head. Would have been better if it was a steel stud! A specialist stud removal guy was called in to do the job.

The turbos were making a fire siren sound, otherwise working OK. Both turbos had bent over blades at the inlet from the filter though when they were removed. Luckily they didn't break and send metal into the engine.

They also put later model calipers on the rear while it was getting repaired so that I can use my 18 inch LR wheel for a second spare on the rear only.

It is all back together now. Just waiting for the electronics expert to come and set up the EGR emulation so that I can take it home and do some more damage to it out on the tracks and towing!

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