Its always a pleasure to find and cure a fault on any zed but when this particular zed started producing a farting sound when pressed in second gear we knew we had to act quickly to save the face of the owner who was getting increasing embarrassed by the sound and worried too.

 

 

Following a road test where the sound was determined to be on the passenger side of the engine it went on the ramp for further investigation.

 

 

The noise was harder to produce when on the ramp but it pointed to either a turbo or manifold gasket so off with the battery to get a closer look from above

 

 

 

From below the next removal was the near side cat and down pipe

 

 

 

So this revealed the turbo and turbo elbow but little else, still not conclusive but it still looked in this area, following a conversation with the owner we got the go ahead to carry on.

 

 

 

The turbo elbow removed and still all looked as it should

 

 

 

A rear view of the turbo with the elbow removed, nice and dry at least.

 

 

 

With space at a premium getting at at all of the fixings needs a two handed ( well four ) approach, Jamie working from above whilst I worked from below.

 

 

Before you know it all undone and turbo off the manifold

 

 

 

So the turbo gasket reveals some of the problem, difficult to see exactly in the photo but the gasket had become paper thin at one side and had started to deteriorate causing some leakage at one edge.

 

 

 

So on to the manifold, lots of WD40 and patience, nobody wants a broken stud now

 

 

 

..............................CONTINUE ON NEXT THREAD...................................

 

Jamie again from above releasing the final nut,

 

 

 

Once removed the manifold tells us we were correct in our diagnosis, the right hand port is blackened from the gasket failure.

 

 

 

Back to the engine and the head goes further in confirming a failed gasket, the most forward port blacked again.

 

 

 

 

Close up of the head port shows although blackened the gasket is in one piece, the lower stud was the problem, not fully located in the head when the nut was tightened the manifold was not flush against ten head.

 

 

 

Careful cleaning up of the faces ready for and a nice new gasket to be fitted.

 

 

 

Many hands again make fitting the manifold back a simple job.

 

 

 

 

Sorry for the blurred photo of the refitted manifold, clearly getting excited now!

 

 

 

A few nuts bolts, pipes, brackets etc. and the turbo is back on

 

 

 

So all back in place, after priming the oil way to the turbo the engine started first time, a gentle warm and all sounding good again, a subsequent test drive and I was pleased to report back to the owner that his zed was no longer sounding like a comical fart in the joke bag.

 

For the most part the cause of the noise was not failed gaskets but the turbo and manifold fixings were not tight, this does suggest at some other time work has been done in this area and poor attention to detail had resulted in a good job going bad later.

 

Jeff TT

Edited July 30, 201015 yr by JeffTT

Bloody hell Jeff, that looked like a fun job, good job it was on the passenger side eh?

 

Nice one.

Great job :) Can we see it done on the drivers side as well please :thumbup::thumbup:

 

Marty

Didnt think you needed to take the engine out as you had said..... !!!

Didnt think you needed to take the engine out as you had said..... !!!

 

Jeff & Jamie are professionals, they do this stuff for a living. What happens half way through if you have a siezed bolt/nut??..... entrust it to Jeff in the first place :D

Well done lads :dance:

 

I didnt know you could do a turbo withthe engine in place?? can you do the other side to??

Nice one jeff and jamie!

You must get alot of job satisfaction, one of the best feelings you can get. imo:D!

Is that A turbo changed with the engine in Place ?

 

Well done you finally seen the light :)

i really wish that was a write up for the drivers side turbo lol

 

But well done on what seems impossible.

Great read Jeff and good work on finding and fixing the problem, nice clean zed to.