Blowing between turbo and exhaust manifold

[Dunx]

Does anyone have any experience in removing the turbo from a 97 E300TD (S210) engine? I have an exhaust leak at the flanges between the turbo and the exhaust manifold. Are there any gaskets in here or is it likely to be a warped face causing the leak?

Thanks in advance,

Duncan

 

[Dieselman]

The turbo should just unbolt. remember to undo the oil feed and pull the return pipe.
iirc there is a gasket.

 

[Dunx]

I've just noticed the exhaust manifold is cracked too (oh joy!). How big a job is this likeley to be to replace? Am I likely to sheer the manifold mounting studs?

 

[Dieselman]

I've just noticed the exhaust manifold is cracked too (oh joy!). How big a job is this likeley to be to replace? Am I likely to sheer the manifold mounting studs?

It shouldn't be too bad. The studs are non ferrous to stop corrosion.

Any pics of the crack, it's unusual to crack. Have you been caning it from cold or driving through water?

 

[Dunx]

It shouldn't be too bad. The studs are non ferrous to stop corrosion.

Any pics of the crack, it's unusual to crack. Have you been caning it from cold or driving through water?

Thx Dieselman. No pictures yet, but I'll try and get some tomorrow (with the manifold still in situ).

I've had the car since August and don't really thrash it, especially when cold. The crack is behind the turbo flange. It has an aftermarket cat (Walker, i think) which doesn't fit too well and I think the idiots that fitted it may have stressed the manifold.

 

[Dunx]

Here are the pictures of the crack. The first and second pictures show the crack near the turbo flange. The third picture shows two missing studs at the front (No 1 cylinder). Looks like someones had fun with this before!

 

[Dieselman]

That doesn't look too good.

it looks like the manifolt to turbo studs have bee overtightened to compensate for the missing gasket. This has stressed the flange and manifold.

Contact mercland for a replacement.

If you fancy some extra performance now is the time to have a bespoke manifold made up. Markku had a contact that could do this.

 

[Dunx]

Best price I got was from Dronsfields for the replacement manifold. The warranty was 90 days too as opposed to 30 from the others. I should have it on Tuesday. Not looking forward to drilling out the old studs. Don't suppose you know the thread of the studs so I can re-tap the holes? Or should I go about this another way?

Not sure I need a custom manifold, as my current fuel consumption is absolutely terrible. Average is 25mpg, pushing to 29 on a long run!! I think this car was chipped by a previous owner, as well as adding 18" AMG copies with the wrong offset (35) so they rub against the upper wishbone knuckle bolt!

 

[Dunx]

BTW, thinking of adding a 211 gasket from the E320CDI engine between the turbo and manifold flanges as there isn't one listed for a 210, according to my local Merc dealer parts dept. Not sure if it will fit, but worth a try!!

 

[Dieselman]

Best price I got was from Dronsfields for the replacement manifold. The warranty was 90 days too as opposed to 30 from the others. I should have it on Tuesday. Not looking forward to drilling out the old studs. Don't suppose you know the thread of the studs so I can re-tap the holes? Or should I go about this another way?

Not sure I need a custom manifold, as my current fuel consumption is absolutely terrible. Average is 25mpg, pushing to 29 on a long run!! I think this car was chipped by a previous owner, as well as adding 18" AMG copies with the wrong offset (35) so they rub against the upper wishbone knuckle bolt!

Use an ezi-out on the broken studs. If the studs aren't broken off flush then a stud puller should do the trick.

A custom manifold may improve economy due to reducing backpressure.

Ah, the joys of chipping...super high EGT.

 

[Dunx]

Ah, the joys of chipping...super high EGT.

Do you think the higher temps may have contributed to the cracked manifold?

Is it possible to return it to standard (altho not sure I fancy the 30 bhp drop!)? I think it's a Superchip, although not taken the ECU out to look.

 

[Dieselman]

Do you think the higher temps may have contributed to the cracked manifold?

Is it possible to return it to standard (altho not sure I fancy the 30 bhp drop!)? I think it's a Superchip, although not taken the ECU out to look.

Well look at it this way. It's a piece of cast iron that expands as it gets hot. Add more heat to the combustion process and that is going to heat the exhaust manifold hotter and quicker.

Buy and fit an EGT gauge to see what temperatures are being reached. Also work on getting more air through the engine as that will ballance the air/fuel ratio and bring down the cylinder temperatures.

The maximum pre turbo temp you want is 1300F or 700C.

Ways to pass more air; clean intercooler and fit larger one if you can, polish turbo innards, fit free-er flowing exhaust and air filter and induction trunking.

 

[Dunx]

I've replaced the manifold and also had to replace the exhaust. The Walker system fitted to the car when I bought it was a poor fit (slightly short and the CAT was a lot smaller. The end was also at the wrong angle to properly mate with the down-pipe) and I think this is what stressed the manifold causing it to crack, probably aided by the higher EGT's.

I also had original fuel and boost maps put back into the ECU so hopefully fuel economy should improve.

I've attached photos showing the cracks in the manifold. The turbo flange was also fairly dished.

 

[horatio]

Sorry to dig up an ancient post but I've got a blow between the turbo and exhaust manifold on my E300TD - I called MB but they can't find a gasket on their system.

My car doesn't appear to have a gasket but I assumed a bodger had removed it in the past - especially given the phots in this thread clearly show a gasket.

Should I just smear in some exhaust paste and re-fit?

Thanks