Freelander 2 noise following exhaust manifold removal.

Hello,

Recently replaced turbo on my 2011 ed4. I had to take off exhaust manifold to drill out a broken stud connecting the egr pipe. Since then its making an awful noise. Does this sound like an exhaust manifold problem? Some exhaust fumes seen coming out the bonnet on switch off.

Thanks

The manifold on these engines is a strange design, especially the fixings arrangement.
Did you use a new gasket?
Did you fit all the studs, spacers and nuts in the correct sequence? How did you separate it from the EGR valve?, didn't force the flexible EGR pipe which can crack if too much force is applied.

To be honest it sounds like the down stream pipe flange isn't sealing. Did you connect the turbo to exhaust clamp correctly, and did you fit a new sealing ring?

Thanks for your reply!

I did fit a new gasket. Im guessing I did not fit the studs, spacers and nuts in the correct sequence - just evenly. I didn't use new nuts either and did not use a torque wrench - perhaps then this is the likely culprit. Havn't been able to find fitting instructions for this anywhere but perhaps not looking hard enough.

The egr pipe I had to force as it was partially being held on by the sheared bolt but on inspection it was intact with no visible cracks.

Hopefully it is the down stream pipe flange. It seemed to marry up correctly and a new sealing ring was used. The clamp that keeps both surfaces in place seemed too narrow as I couldn't get it to cover the entire circumference where the turbo and exhaust meet. But they seemed to be held together solidly despite this. I'll redo this part first.

I would get it up in the air, and see if you can feel the leak. As I can hear the turbo whining, I suspect it's the clamp to the pipe, which hasn't pulled the flange together.
If it was the manifold leaking at the head, the noise would contain less turbo whine.

The manifolds on these engines can be a pain to install correctly, having just finished my top end rebuild a couple of weeks ago.