Bimmer777

So my GL developed an exhaust leak. It looks like its coming from below the turbo, likely either uppipe or downpipe. Does anyone have experience with this? I've searched and haven't gotten much on it.

I don't think i'll have the time to undertake the job myself now so looking for a good mechanic who can do this in Northern NJ or NYC area for a reasonable price. Please let me know if you have any recommendations.

alx

Wow. Never seen this. I think your turbo to manifold seal is bad. If you are mechanically inclined and have a good set of tools you should dive right in. Search for om642 oil cooler seal replacement procedure and while at it replace also the turbo seal since you will be going "through" it when removing the turbo.

Bimmer777

Unfortunately I don't have time right now to undertake this job. I don't think it would be particularly difficult other than reaching couple bolts behind the turbo, but will be time consuming for sure. Trying to find a reputable shop now to do the job. Will have them replace all the seals and gaskets that they can while there. Also, may as well put in updated oil cooler seals so I don't have to deal with that again. Anyone have the part number handy? Otherwise i will search for it later.

Bimmer777

Sooo, I cannot find a shop I trust enough to do the job so will undertake this myself in a few weeks time with the help of my Rally shop friends.

I want to order parts so I am ready to fix any possible problem once I get behind there. Does anyone have a source for diagrams where I could see all the gaskets and bolts with part numbers? I want to order all new hardware and replace every possible gasket so its all new back there. Also planning to replace oil cooler seal. Thanks for the help in advance.

johny75

BTW, that orange seal does not look right either (the big one that seals the intake to the turbo), it is not seated correctly. Do you see the little orange tabs that stick out of it?.. they should be inside the plastic slots of the intake. I am not saying that is the leak issue, but something else to take care of.... Ask any questions on that, I recently ordered a set for mine and replaced the old squished and soft seals.

Bimmer777

I see what you are talking about. That is not the problem but I will get a new orange seal and put it on properly. Thank you for that.

Separately, I have a question on the little orange tube that goes into the intake from the side. Its also in the picture. Mine was sticking out a bit and moves pretty freely in and out, partly because its oily. Is it supposed to be like that or should it be clean and pretty tight in the intake?

johny75

Yes, the smaller seal was doing the same on mine. That happens over time as it gets old, and it needs to be replaced. The new one seals really tight, you will see! I purchased both for no more than 36$ online (ebay, etc..)., it is worth the money, I would recommend changing them every 3 years or so. You likely have seeping oil from the old seals beneath.

Bimmer777

UPDATE - had a chance to fix the problem with the great help from my Rally shop since I really didnt trust anyone else with the job. Turns out it was the EGR pipe gasket, the one that goes into the aluminum EGR valve. When taking it apart we found that the bolts were loose on the pipe, especially one one them. Took it off, gasket pictured below. Turns out the threads were stripped on one side. Have no idea how it happened but the aluminum was soft there as we had to put in a large sleeve (new thread) in since smaller one was pulled right out when we tried to tighten it down.

Weird problem to have. Maybe poor quality aluminum so bolt stripped the threads with time and then gasket went. Anyway, happy to be all fixed now.

DennisG01

Was just reading through your thread, trying to learn as much as I can about this new (to me) vehicle. Thanks for the follow up!

I noticed your "orange seal" and the "tabs", along with what Johnny said about it. As coincidence would have it I just had my plastic intake off a few hours ago. While it was out, I removed the orange seal to inspect. When I put it back in, mine looked exactly like yours. I didn't see a way to get the seal any further in. There are smaller, round, tabs that do pop into holes in the plastic piece (in your picture, they are currently black from the smoke). But it seems like those larger, square tabs are there to keep the orange seal from sliding out of place as the intake is put on. Am I thinking of that wrong?

Captincvmn

Did you do the oil cooler seals while in the area?

clvincent

on the orange seals there are 2 different styles

they upgraded the entire black piece that hooks to the turbo and now there are at least 2 different style orange seals

the older ones i think are more rounded, the newer ones have a big square that slides in

Bimmer777

I replaced both orange seals. The bigger seal that sits on the turbo was a different design than the one on my car but I still put it on and it went on tight. The new seal did not have the big tabs sticking out. It just had the small ones that are there for alignment into the plastic intake tube. I guess that part number was updated at some point. Also, the seal was still orange and not black.

I did not do the oil cooler seals even though I bought them. We did not have to take off much to get to the EGR pipe. Changing oil cooler seals would have required many more hours of labor. Mine are not leaking yet so we decided to address the problem when it actually happens.