I finished up my motor build. I finally got to get the car running and notice that there is a exhaust leak. I put my hand under the epm dump and there is an exhaust leak. First i thought that the wastegate (fp 25psi) was stuck open, so i exchanged it with a forge 18 psi wastegate just to see if that was the issue. It wasnt. I know that i am using my exhaust gaskets and they are on correctly... I just cannot figure this out. Any help will be appreciated!

EDIT: we even took the wastegate arm off the turbo, and manual shut and open the flapper and its still leaking.

 

YOU CAN HEAR IT IN THIS VIDEO

http://youtu.be/uu9PXZldz4Y

 

wga not preloaded enough? thats what my car did when i installed my forge unit but did not preload it enough

 

So u think i should take ethe cotter pin out and turn it in down?

 

thats what did it for me. it had to be a lot tighter than i imagined it would. i ended up tightening it so it sits a bit more than half of the hole in the arm below the pin of the flapper it has to go on. if you cant pull it on there use the claw end of a hammer to grab and pull up on the arm. i think that sounds confusing but i dont really know how else to word it haha. if it doesnt seal then try another half turn tighter and so on.

 

Ok i will try that... I also dont get a boost reading on my boost gauge. It reads 8-10 in vacuum at idle then up to 16 while driving and when i hit the gas, the turbo spools, but only reads 0 psi. Maybe this might help. (oh and im only on a basemap since the build. I have to wait until jestr gets back from vacation on tuesday)

 

yea if your wastegate flapper is not being held closed due to the actuator not tight enough it wont really build boost because all the air is just going out the wastegate

 

Thanks for the help... Im going to pay the car a visit now

 

Ok i adjusted the wastegate arm all the way to the inside and it isnt the issue. i still have an exhaust leak from the dump. Any other ideas folks?

 

Is your 02 dump tube completely seperated from the exhaust steam? Or is it like most dump tubes that are open following the stock gasket shape? Hope that makes sense.... If its not completely seperated by design, then your gonna have exhaust gas coming from the dump tube no matter what. Thats how mine is.

 

It has a divorced style gasket. So your o2 dump leaks also?

 

Ok, so is your 02 dump also divorced? or is it just the gasket? Sorry just trying to fully understand your situation. If its just the gasket thats divided but not the actual 02 housing, then your gonna have exhaust gas coming out the dump tube. If its totally seperated in the housing then yours is different from mine, and should not be cross flowing. The only other thing I could say is tighten the pre-load.

 

check if your turbine housing is sealing at the o2 housing area if its perfectly flat. Use some copper paste to assist in the seal. ALso, make sure your flapper is not bent at all. Mine was bent a slllliiiight amount and it caused many issues.

 

Yep copper sealeant on both sides of gasket....hell when i did my o2 i didnt even use the gasket...just a couple of good coats of copper on both sides an has never leaked.

GL!

 

the gasket and dump is divorced.

the next thing for me is to check the flapper. Now if the flapper is the issue. How can i go about getting another one? Im running the fp black... Can i use a flapper from a stock evo 8 turbo with the 10.5 hotside?

i guess after i check the flapper i can re-install it all with some copper sealant.