Defender TD5 Wastegate adjustment

Put the T where? cos if it was on the pipe which comes from the intercooler to the wastegate valve at that pressure the valve should be fully opened...i dont want to re-read the whole thread to see if it was asked or not...is the EGR properly bypassed?

Between the intercooler and turbo yes. The egr is completely blanked off and removed

It may be that the waste gate is only opening partially as it's difficult to see I can only see it moves

if you get 23psi on that pipe it means that the turbo is working and the leak is between the intercooler and the MAP sensor or a leak within the wastegate valve, next time you make measurements clamp that pipe after the gauge, as i said at that pressure the rod should be pushed forward ... or if the MAP is 100% ruled out it can be a wiring issue on it's circuit, isnt the hole where the sensor goes in full with gunk?

let's hope that your gauge is not reading higher than the reality

It's clean! To be honest I'm losing the will to live with it. I'm hping it's a problem with the wastegate as we can't see a problem anywhere else

yes, very odd... good luck with it, eventually double check the gauge to make sure it reads well

You checked if the inlet manifold gasket is intact? Not blowing the air out of there?

I did consider just replacing the inlet manifold gasket anyway but it's such a bitch to get off we just sprayed it (and everything else) with soapy water and couldn't see any leaks anywhere.

Really? I pulled mine off in less than 30 mins! Its actually surprisingly easy, though I can't imagine you'd be able to see the bottom of the inlet by doing that. It would be worth doing to clean out the gunk in the inlet and replace the gasket anyway imo.

This does sound like a very unusual problem! Would be able to do a run down of what you have tried and the result/symptom so far? Make it easier for the rest of us to try and diagnose your issue

I'd like to find out for myself in case it ever happens to me! One thing I would say for sure is 23psi is very high. Standard should be 13/14psi, ~18psi before "limp mode" kicks in and 22psi before you hit lag. (from personal research/testing over the years)

Would we not hear the air escaping from the inlet? Half the bolts you can't even see so well done for getting it off that quick!

Not sure you would tbh especially if its at the bottom. Thats true but again surprisingly easy to access! Plus the bolts arent super tight in there like the exhaust manifold. I think all I used was a deep socket and an extension.

Drop the fuel cooler (but leave it connected), unbolt the oil cooler pipe at the bottom, unplug the glow plug cables and disconnect the dipstick. Then start undoing the inlet bolts. Shortly after it'll be off.

I was expecting it to take me half a day, got cracking at around 10am it was off around 10:30 I was shocked haha

bankz5152 said:

Not sure you would tbh especially if its at the bottom. Thats true but again surprisingly easy to access! Plus the bolts arent super tight in there like the exhaust manifold. I think all I used was a deep socket and an extension.

Drop the fuel cooler (but leave it connected), unbolt the oil cooler pipe at the bottom, unplug the glow plug cables and disconnect the dipstick. Then start undoing the inlet bolts. Shortly after it'll be off.

I was expecting it to take me half a day, got cracking at around 10am it was off around 10:30 I was shocked haha

Click to expand...

Cheers it's not going anywhere in a hurry and I do have a gasket so might as well give it a go

Indeed, get some Mr Muscle Oven Cleaner as well, fill it up and let it soak for 30 mins, then jet wash it to hell.

Gives you a chance to check everything around that area as well.

bankz5152 said:

Gives you a chance to check everything around that area as well.

Click to expand...

Lol What i should do is remove the engine and completely rebuild it!

hahaha I know the feeling! Though im sure you'll solve it! Tell ya if you havnt got it solved by the 13th of November I'll come and have a look see if I can help at all! As I'll be heading up that way that day

bankz5152 said:

hahaha I know the feeling! Though im sure you'll solve it! Tell ya if you havnt got it solved by the 13th of November I'll come and have a look see if I can help at all! As I'll be heading up that way that day

Click to expand...

If it's still ongoing then just bring a can of petrol and we'll go to the pub!

I took my turbo in to a place at Northampton yesterday and they have identified the following:

• Centre Housing Rotating Assembly has worn journal bearings & worn thrust bearing
• Worn bush in wastegate
• Carbon build up
• Fine foreign object damage to compressor wheel

The repairs worked out the same as a new turbo, so I now have a new turbo. Will still need to leak test the inlet manifold to rule it out.

Did a leak test today with a smoke machine I know it's not ideal but couldn't see any leaks so turbo on over the weekend and see how it goes.

Good luck! Id also lengthen your wastegate drop the boost down to about 18psi

bankz5152 said:

Good luck! Id also lengthen your wastegate drop the boost down to about 18psi

Click to expand...

Yeah cheers it'll be at standard length for a few weeks at least until it can be trusted again!

Just a thought, but seeing as I have newer (15p) loom than I should have could this affect the throttle signals? I am wondering if it's expecting a 3-track signal or something ? Not sure how I would check