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carrotbay

Member Since: 18 Aug 2013
Location: Northants, UK
Posts: 702

2008 Defender 110 BMW M57 3.0 Diesel XS CSW Auto Santorini Black

Turbo Gasket - leaking again :(

This is the fourth time I'm going to have to change my turbo to manifold gasket in 30k miles. I'm getting pretty quick at it but that's not the point!

I've tried standard gaskets, Nak gaskets and turbo gasket paste.

Obviously one side is warped, but which one is more likely, turbo or manifold?

Thanks 2008 Defender 110 XS SW - M57N2 / 6HP28X

28th Feb 2016 10:01am

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20549

Have a chat with Gary @ Alive tuning.
He may have a solution or at least plenty of knowledge of such things.

28th Feb 2016 1:59pm

Bogblaster

Member Since: 04 Jun 2007
Location: Glawstershire
Posts: 119

2016 Defender 90 Puma 2.2 Adventure Corris Grey

Both AndrewS and I had this problem back in 2007/08, sounds like a blade of grass between your thumbs?

IIRC LR changed the gasket set to a much thicker one, but I've had more than 3 sleeps since then.

I'm assuming yours is re-mapped?

That was the trouble with mine.

BB 2019 MY Disco 5 HSE Lux
Audi A4 Avant 3.0L TDI Quattro - WOW
2016 90 Adventure

28th Feb 2016 2:30pm

Alive Tuning

Member Since: 01 Mar 2010
Location: Louth
Posts: 610

The ROOT cause of this happening is high EGT, distorting the mating face of the exhaust manifold, and sometimes the mating face of the turbocharger. It's usual to see the outer points of the triangle that have distorted, leaving a gap between the faces and often snapping the bolt/stud.

Installing the thicker (repair) gasket actually increases the stress on the already compromised mating faces, as when tightening, you'll be trying to bend back the casting.

The best repair is to remove the manifold and have the faces checked and machined flat.

Click image to enlarge

Click image to enlarge

Assuming the mating face of the turbo to manifold flange is true, then rebuild using a genuine gasket.

Ultimately there is a risk of this reoccurring and the reasons the EGT's are getting so high needs to be addressed.

Kind Regards,

Gary.

29th Feb 2016 12:57am

carrotbay

Member Since: 18 Aug 2013
Location: Northants, UK
Posts: 702

Thanks for your replies. Yes, it is remapped and in the early days, before I knew better, it was remapped without any other modifications such as intercooler etc and obviously got pretty hot.

I'll get the manifold off and get it checked and machined if necessary. (This may be the excuse I needed for a hybrid turbo

) 2008 Defender 110 XS SW - M57N2 / 6HP28X

29th Feb 2016 7:02am

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

2013 Defender 110 Puma 2.2 XS DCPU Keswick Green

Alive Tuning wrote:
The ROOT cause of this happening is high EGT, distorting the mating face of the exhaust manifold, and sometimes the mating face of the turbocharger. It's usual to see the outer points of the triangle that have distorted, leaving a gap between the faces and often snapping the bolt/stud.

Is there any common cause of high EGT on an unmapped engine?

27th Dec 2017 1:40pm

Caterham

Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6312

2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey

does the map not cut back the power when temps get high?

I'm running 450Nm for approx. 50k miles now (100k miles total) and the engine has been one of the few areas where nothing seems to have been ok?

not exactly helpful but makes me wonder whether things aren't quite 'right'? perhaps addressing the high temps should be resolved rather than simple replacing the gasket?

27th Dec 2017 6:52pm

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