So I was up a mountain when I heard a snap or something from the engine bay. Initially I didn't really pay any attention to it, but I realized throughout the day that the car was getting louder and louder.

I had an exhaust leak or something near the turbo before, but now it's as loud as the car was when I had straight pipes. Louder, even.

The excessive noise is definitely coming from the engine bay. I'm also having difficulty building boost.

Initially I thought that the wastegate might be stuck open, but it seems to be fine.

I'm guessing that the problem is either a severely cracked exhaust manifold or a snapped turbo stud.

Do you guys have any thoughts?

It's an S5 Turbo.

 

I don't think anyone will be able to help because it could be many things. I suggest you take a look in your bay!! Post pictures if you're not sure.

 

If your exhaust manifold is in-fact cracked, I would assume you could take it off and look at it to tell without too much difficulty. You could pressure test it too.

I mean, if it's that loud, I'd imagine it would be fairly noticeable..

 

I'm definitely going to pull it off and see what's up. There aren't too many points of failure between the exhaust pulse and the turbo, haha.

I was just kinda venting.

Do you guys know if i I have to remove the intake mani to get the exhaust manifold off?

I know it's a bad time when I'm hoping it's /just/ a snapped turbo stud.

 

Best case scenario: a nut is loose or fell off, or the gasket is blown out

Worst case scenario: the exhaust manifold is severely cracked

 

and fix it asap or it will deteriorate to the point that you will need new(er) components.

no you don't need to remove the intake manifold to remove the turbo.

 

Partially drain the coolant from the radiator, then remove the intake, downpipe, TMIC, ACV (optional). A wrench works in most cases for the exhaust manifold nuts, but they can be really tough to break loose. A ratchet with an extension will work for the top, front one.

 

Thanks for the tips. I'll get at it this weekend

 

Where you running proper exhaust hangers? I heard of studs breaking when people cut corners with zip ties/metal bands etc.

 

Well there are a handfull of zipties involved, because the Racing Beat hardware didn't really explain how the Y-pipe would work with the hangers, but yes I am using actual hangers.

I'll be digging into it this afternoon.

 

This problem is silly and I'm pretty relieved about that.

Obviously the right thing to do would be to replace the gasket, but would it be horrible just to kinda tighten things up?

 

^ Is that how you found it?... Or did you loosen the bolts up and you're referring to the gasket?

 

That's how I found it. Embarrassing, yet relieving.

 

I tightened everything up and she's running much better now. Eventually I'll replace the gasket.

On a side note:

Does anybody here have a racing beat downpipe?

I can't seem to get a bolt on the stud closest to the passenger's fender. The pipe is too fat.

What did you guys do about that?

 

You have the wrong nuts on the exhaust manifold. They don't lock, and it's just going to jiggle loose again. Get these:

M10-1.5 Exhaust Lock Nut Copper Plated Steel 14mm Hex

I bought one bag of 25 and have used them on every exhaust component and they work great. I also made a copper exhaust manifold to turbo gasket, and it seals great.

 

That is a great idea. ^

Glad to hear.

I have a Racing Beat downpipe. I have had to remove and reinstall it a few times, for various reasons... So, I know exactly what you're talking about. I just use the shortest 15mm open end box wrench I can find. Then it is patience and wrenching.

 

you can reuse the gasket, you are missing the lock washers. get those and tighten them down good.

 

Those lock washers look pretty nifty! I just bought some. Thanks!

So dwb, are you saying that the nut will go on if I just use enough willpower? haha

 

Yes... You must concentrate, young padawan.

Just be patient. It might take you 5 minutes, it might take you 25 minutes... But you'll have peace of mind once you know it is on there damn tight. You may even want to slightly loosen the other two bolts when you start getting this one to bite. And then tighten them all evenly when you think they're around the same point.

 

Thanks for the help guys. I really appreciate it!