Engine ticking noise after cleaning Inlet Manifold. Listen..

[grogan197]

You were right. Not sure how I missed that! Hope I haven't caused myself any new issues by chucking a load of air in through there

I'll go and test the pipes from the MAP sensor to the intake in a few mins once the glue has set!

[grogan197]

I tested for leaks from just after the MAP sensor to the intake and there is a boost leak. I couldn't spot any hose damage but I plan on having a better look when the light is better tomorrow. I have also ordered a blanking plate for the EGR so I can rule out any possible leak there. Hopefully it will turn out to be a damaged hose!

[ned]

Have you put all the pipes back on fully, no kinks and done all the jubilee clips up tightly? I didn't tighten up a pipe on the intercooler once and shat myself when it blew off It sounded like a bloody tank.

Is your egr at the back under the turbo like mine, if so get the blanking plate with the slots for the bolts (as oppose to the one with the two holes) its much easier to undo the two 8mm bolts and slide it in instead of removing the bolts and struggling to get them back in.

I want to remove and clean my egr to get it operational again but I'm a bit dubious of doing it because of its location, I dare say after 205,000 mile it'll be completely blocked up. N

[grogan197]

Yes the EGR is in the same place on mine as yours. I have ordered the blanking plate already but went for one of the ones that slide in as figured it would be a lot easier. Thanks for the tip though!

Can't see any kinks etc and did the jubilee clips up pretty tight. I'm hoping that there's a split and that I made it worse getting rid of the gunge that was coating all the hoses.

[grogan197]

I've blocked off the hose that goes into the inlet manifold to test the section between the outlet on the intercooler and the inlet manifold, no leaks detected there so the leak must be the intake manifold itself. I have ordered a set of replacement gaskets, fingers crossed that will sort it!

[mattt429]

Forgot to say the other day, have u checked the Inlet plenum for cracks or splits? Easy repair if it has

[grogan197]

Forgot to say the other day, have u checked the Inlet plenum for cracks or splits? Easy repair if it has

I haven't spotted any. I'll take it off to pop the new gaskets on when they turn up (tomorrow with any luck) so I'll give it a good visual check then!

[grogan197]

The new gaskets came today so I've fitted them on. I've only leak tested it while it's sat on the drive but it does still seem to be leaking air far quicker than it should be. I had a good check over the manifold and spotted one seam that looked a bit iffy so I sprayed it with leak detection spray but the leak wasn't coming from there

You can hear some air noise when you take the filler cap off, but I can't feel any airflow there. Hoping it's not leaking to there as guess that's a more serious engine failure. Piston rings knackered or something?!

I'm going to get some smoke matches to try filling the intake with smoke and then put it under pressure and see if I can spot the leak then.

I could also do with getting it out for a drive to check if any symptoms have changed / improved after changing the seals but I'm mid wheel bearing change and waiting for a couple of parts so driving it is probably going to have to wait till after the weekend.

[mattt429]

The new gaskets came today so I've fitted them on. I've only leak tested it while it's sat on the drive but it does still seem to be leaking air far quicker than it should be. I had a good check over the manifold and spotted one seam that looked a bit iffy so I sprayed it with leak detection spray but the leak wasn't coming from there

You can hear some air noise when you take the filler cap off, but I can't feel any airflow there. Hoping it's not leaking to there as guess that's a more serious engine failure. Piston rings knackered or something?!

I'm going to get some smoke matches to try filling the intake with smoke and then put it under pressure and see if I can spot the leak then.

I could also do with getting it out for a drive to check if any symptoms have changed / improved after changing the seals but I'm mid wheel bearing change and waiting for a couple of parts so driving it is probably going to have to wait till after the weekend.

Sorry to hear its still on going has your van got the short 90 degree pipe, think it goes from metal pipe to inlet? my mate said they are prone to splitting?

[grogan197]

Finally got round to road testing the van today after changing the wheel bearing and a few other bits. I had Forscan going when I drove it and gave it a good blast to check the sensor readings. The MAP sensor is going up to around 3.9v so just over 20psi of boost which seems pretty healthy so I think I can rule out the boost leak.

The noise is still there though, but this van is usually not driven hard so I think I'm noticing it more when I put it under a heavy load. I'm going to see if I can get a second opinion on the noise, if it is the little end bearing I think I'll be getting it rebuilt as only had this (used) engine put in 18 months ago

[grogan197]

Ok, I just went out for another drive and got the mrs to video the noise for me. Much better quality than the first one and you can see the RPM. Any idea https://youtu.be/eSp7nP0WLI8

[ned]

That sounds like a miss fire to me, have a look and see if any of the injector plugs are loose, and check the injectors themselves are tight, mine sounded like that today with a short nozzle un programmed injector in. N

[grogan197]

Yeah I was thinking it would be nice if it was something injector related. I should have a bit of time to look at it on Thursday so I'll give them a tighten and check the electrical connectors. I'm thinking of picking up a compression tester too so I can see if a cylinder seems suspect.

[grogan197]

I did rev it hard today to see if it went into limp mode (it didn't) so that probably (guessing) rules at the electrical connection on the injectors, one being loose is certainly possible. They have been in for over a year but when I fitted them I used a pretty crap torque wrench so wouldn't surprise me if it wasn't particularly accurate

[grogan197]

I think I am on to something now. I just tested the air intake on each cylinder individually and found that the cylinder closest to the drivers side looses pressure very quickly and you can hear air noise through the oil filler. On the other three cylinders the pressure held and there was no noise.

At this stage it looks like a valve is the likely issue. Maybe something got down the intake port and has now damaged a valve after I had the manifold off for a couple of days or maybe it was just coincidental timing

I'm going to assume there is something that went down the intake port and try and retrieve it. Not sure the best way of doing that, maybe a hose stuck to my hoover? I do have a little probe camera thing but it ends up covered in soot before you can see anything down there. Bloody EGR valves chucking gunk everywhere