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      02-07-2013, 06:37 AM   #1
nicktyler
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How much of the exhaust should I replace?

Hi

I have the noisy flap on cold start in my car and I'm wondering if anybody knows exactly where it is. I'm thinking on replacing the whole exhaust from downpipes as I am getting the turbos rebuilt but I don't know if a back box is enough to remove the flap. I don't really want to have to replace the full system including secondary cats but if most of the back needs to be replaced it might not cost much more to go the whole hog.

Cheers

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      02-07-2013, 08:47 AM   #2
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The flap is on the nearside exhaust pipe tip.

It is most likely to be the actuator and hence a cheap fix. Get under the car and apply vacuum to the actuator and check the flap closes/opens...

If wanting to replace the backbox alone I'd go with a BMW performance system.

Do you have catless downpipes? Bastuck back box sounds awesome with CL DPs!

I wouldnt replace mid pipes unless you want it LOUD...
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      02-07-2013, 09:16 AM   #3
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I have tried the unplugging in the boot 'golf tee mod' alternative and it makes little difference so maybe that is an indication that the actuator is buggered.

I am planning to get my turbos rebuilt (wastegate rattle) and fit downpipes at the same time to save on labour (hence the WTD in classifieds), and of course spending that much money it would be nice to have some performance gain. I have the Evolve-R cable so will get those guys to sort em out a new map. I'm happy with the noise which is why it's hard to justify so much money on a new exhaust and to an extent turbos just to stop an embarrasing noise.

Do you think there is a way of just cutting the flap out of the stock exhaust if it is close to the back?
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      02-07-2013, 09:31 AM   #4
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Does it really bother you that much?

Mines done it since the car was about 6 months old, just never really thought much of it.

It's just a zing and gone in half a second.

But just to check, look up the nearside exhaust pipe and get someone else to start the car, the flap (easily visible, only 2 inches up the pipe) will be OPEN before you start it and it will close when it cold starts, then it will open after fast idle (about 30 seconds).

See when the rattle happens, i.e. during starting, or closing or opening etc.
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      02-07-2013, 10:12 AM   #5
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A zing and gone? My rattle is pretty loud and continues until the cold start cycle is complete and the revs settle. So about 45secs.
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      02-07-2013, 10:38 AM   #6
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Turns out it's not the flap! The rattle comes from the drivers side of the engine bay.

That's wastgates right?
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      02-07-2013, 01:12 PM   #7
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If its a ticking noise its probably the injectors.

WG rattle won't just be when cold..
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      02-07-2013, 03:55 PM   #8
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....although when mine were loose, prior to resetting them they did rattle on the fast idle quite noticeably, much louder with decat dps though.

Post a video!
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      02-07-2013, 06:06 PM   #9
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Quote:
Originally Posted by phil200tdi View Post
If its a ticking noise its probably the injectors.

WG rattle won't just be when cold..
They do rattle all the time it is just very loud on the fast idle during cold start.

I will be replacing the turbos anyway so hopefully that will fix it.
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      02-07-2013, 08:07 PM   #10
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Quote:
Originally Posted by nicktyler View Post
They do rattle all the time it is just very loud on the fast idle during cold start.

I will be replacing the turbos anyway so hopefully that will fix it.
from what i have read. these turbo rattle will come back after being used for some time. its the waste gates that has come loose.

check this vid and you might understand

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      02-08-2013, 03:13 AM   #11
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Thanks for the vid. That does illustrate it quite well. I'mactually having them rebuilt on an exchange basis by a company called Essex turbos who use upgraded components in the wastegate assembly so the problem should not return. It's not an exact like for like swap.

So much for 'german engineering' it's a bloody Jap turbo!
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      02-08-2013, 07:23 AM   #12
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What's the price at Essex turbos?

Do they do it on an exchange-refund basis?
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      02-08-2013, 09:29 AM   #13
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The price is 900+vat for both turbos on an exchange refund basis. Like I say they tell me they build in a fix for the wastegate rattle so it seems a pretty fair price. they come recommended by Prestige Veichle Repairs (also in Essex) who will be fitting them.
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      02-08-2013, 10:05 AM   #14
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That seems a lot?

I thought Turbo Dynamics (world renowned turbo bods) do an exchange with new improved wastegate mechanism for circa 200 per unit?
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      02-08-2013, 10:45 AM   #15
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I have also contacted Turbo Dynamics. I have no prices yet (let you know when I do) but they said they are developing a 'wastegate only' rebuild/fix which will be ready in a couple of months.

Maybe te wastegate fix will eb 200 per unit but I would be surprised if they aer rebuilt exchange turbos for that as the lowest price I have seen is on eBay for 300 per unit from some company in Latvia.

Edit: Just spoke to TD and they are 395+VAT per unit but no exchange so need your turbos to rebuild. Also currently no wastgate fix.
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      02-11-2013, 09:00 AM   #16
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They must have been Bullshitting me then, TD offered me the wastegate-only fix for 175+VAT exchange in May 2011 when I first got a rattle.

They said they used a ceramic sleeve insert to stop the wastegate shaft wearing the hole in the turbine casing.

Maybe they gave up on that one
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