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I believe I have a lot more stuff in the way so I had to remove more to gain access to all the manifold bolts and have room to work, plus you're WAY more experienced than I am lol. Also your engine is most likely way more organized than mine
THIS bolt is damn near impossible to get at without disconnecting the downpipe.
I wasn't able to get my torque wrench to the rear manifold bolts so I just used a small combination wrench so now I'm going to re torque the bolts with an extra half turn and if that doesn't fix the whistle/air sound then the truck will just sit till spring then I'll completely remove the intake manifold+turbo then install the Felpro gasket/seal kit I have sitting here.
Having to remove the whole top of the engine and intake manifold to get at that O ring is such a BS design 😖😠
You could say that "BS design" part about lots of things about these trucks, AND a lot of other vehicles. Like replacing the alternator on an early model Ford Escape, or a gen 2 Tundra, or water pumps on lots of Japanese cars. Talk about a beating.
Anyway it may not have anything to do with the intake manifold, but you could find out pretty quick if you had a way to pressure test the intake tract.
You could say that "BS design" part about lots of things about these trucks, AND a lot of other vehicles. Like replacing the alternator on an early model Ford Escape, or a gen 2 Tundra, or water pumps on lots of Japanese cars. Talk about a beating.
Anyway it may not have anything to do with the intake manifold, but you could find out pretty quick if you had a way to pressure test the intake tract.
Yeah true enough I suppose!
And yeah I think I'll make one of those DIY pressure testers and give it a go before I tear everything apart again. At least that will hopefully pinpoint the exact area where the air leak is then I can just focus on that area and go from there. Thanks FUZZ
I drilled a hole and put a bulkhead fitting through it. The flat surface bulged out under pressure and leaked around the bulkhead so I made some big aluminum washers to minimize that, and it worked until it eventually blew off the turbo. I used it like that for 10 years until I made the new one last week. Now I'm thinking I could have cut off the flat surface altogether, rendering a very short rubber tube, and clamping a 4"diameter piece of plywood inside like the BPD version. Could probably even get away with drilling and tapping the plywood for an air fitting, if you have a pipe tap.
I drilled a hole and put a bulkhead fitting through it. The flat surface bulged out under pressure and leaked around the bulkhead so I made some big aluminum washers to minimize that, and it worked until it eventually blew off the turbo. I used it like that for 10 years until I made the new one last week. Now I'm thinking I could have cut off the flat surface altogether, rendering a very short rubber tube, and clamping a 4"diameter piece of plywood inside like the BPD version. Could probably even get away with drilling and tapping the plywood for an air fitting, if you have a pipe tap.
Pressure tested it and found air coming out the turbo boot and the boot that connects the tube from the intake manifold to the inter cooler so I removed, cleaned then replaced and unfortunately the whistle/squeal noise is still there so I think I'm going to cave and take it to the shop and have them install the new Felpro gasket kit I have here and just call it a wash lol
I was able to record the noise and this time there was some turbo farts too so I dunno fellas?
BTW when I did the pressure test I mounted my contraption directly to the turbo so I had to remove the tube with the CCV line and when under pressure there was some air pushing out the CCV tube hole and I'm wondering if I was suppose to have plugged it with something or just let it sit open?
On the last pressure test when the CAC boots were quiet I was able to hear air hissing from the area shown below FWIW:
That happened on the 06 I tested last week, and IIRC on mine the last time I tested it too. It sounds like its coming from the turbo to me. I never did figure it out, but I sprayed soapy water all over the intake and turbo and got no bubbles.
That happened on the 06 I tested last week, and IIRC on mine the last time I tested it too. It sounds like its coming from the turbo to me. I never did figure it out, but I sprayed soapy water all over the intake and turbo and got no bubbles.
When I put in that new O ring doughnut I didn't do anything to the turbo aside from taking the boots off and the hissing I heard when pressure testing it could be normal for all I know, but I'll pressure test it again when I have time and use soapy water and see what's what.
If that squeal is coming from the intake manifold due to not being seated properly the air is being forced out when under boost correct?
Sounds almost identical to when the old up pipes had a leak, but all those clamps are good and everything was fine before I changed out that stupid O ring so I dunno 🤨
Ok fellas I'm going to do another pressure test today to check for air leaks and just curious if i should be plugging the CCV hole or leaving it as is?
Ok so instead of doing an air test today I opted to just re torqued the intake manifold bolts......well most of them lol, but before I did I got the engine up to temp and I figure my torque wrench is crap so I just snugged the bolts by feel and now the "Whhheeeee" air sound when boosting is only 1/5 as loud as it was before thank goodness!
So on the next nice day I'm going to remove everything again to gain access to all the bolts and I'll loosen them all then re torque in sequence with a new torque wrench then go over them a second time by hand given each bolt an extra half turn or so. Hopefully that will get the manifold seated nice and snug.
