Post by: Chesto18 on November 01, 2018, 11:55:01 am
Caught it leaking a while back and removed the O-ring, re-greased and refitted to see if that helped. Had the tray off for an oil change the other day and same thing, oil running from the seal and the pipe itself not seated flush against the intercooler. It’s not in danger of coming off as the clip is still keeping it in place, but it’s at least 1cm pushed out instead of being tightly seated as the other pipes are.
Is the only solution a new boost pipe here?
Post by: pudding on November 02, 2018, 11:50:23 am
Post by: Chesto18 on November 21, 2018, 08:10:16 pm
Just a short piece of silicone boost hose that’s flared one end to fit over the intercooler, other side going over the metal coupling on the boost hose.
If I can find one with the correct diameters would this not work?
Post by: muff1991 on November 22, 2018, 03:13:48 pm
at some point I need to fit the forge hoses @Dave aka (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=27661) give me, but not sure if the couplers are any better than the standard ones!
Post by: pudding on November 23, 2018, 10:34:16 am
Post by: muff1991 on November 23, 2018, 12:21:48 pm
I can't remember what the OEM intercooler looks like with the pipe removed. Is there enough of a lip to get a silicon hose over it? That should work. I'm not sure what kind of horrendous turbulence that might cause, but worth a shot!
actually.. you saying that Pud, I don't think this would be a good idea! I had my head in there last night (fitted the forge coupler/hose - still not pleased, will upgrade intercooler sometime) but the inside of the intercooler pipe is the seating point for the hose/couler. almost like a circle within a circle... so air probably wouldn't flow very nice tbf.
Post by: pudding on November 23, 2018, 01:24:47 pm
Post by: muff1991 on November 23, 2018, 02:19:34 pm
Post by: Chesto18 on November 23, 2018, 07:52:31 pm
I guess that airflow wouldn’t be as smooth with a silicone coupling but I’m wondering whether it would benefit overall anyway as the seal between pipe and intercooler would now be airtight. So whether a full seal is more beneficial than flow at this point.
I’ll measure up and see what my options are. The silicone reducers I’ve seen online aren’t expensive, so might be worth a go and see how I get on.
Post by: muff1991 on November 24, 2018, 11:23:10 am
I’d love the S3 option but ATM there are a fair few mods that would take priority.
I guess that airflow wouldn’t be as smooth with a silicone coupling but I’m wondering whether it would benefit overall anyway as the seal between pipe and intercooler would now be airtight. So whether a full seal is more beneficial than flow at this point.
I’ll measure up and see what my options are. The silicone reducers I’ve seen online aren’t expensive, so might be worth a go and see how I get on.
I suppose the best way to find out would be too try it. Like you said, an air tight seal is better than nothing.
Tell you what I tried for a proper tight fit (and convinced it works): wrap a few layers of PTFE tape in the boost pipe groove for boost seal. This pads out under the boost seal making it a little bigger in turn... a tighter fit / better seal (grease seal for easier fitting) and make sure the seal slides in nice and straight and doesn’t try flipping off the pipe. It’s worth a try mate! Don’t go too mad with the PTFE tape otherwise you’ll never get it in lol. Find the happy medium
unfortunately it will not stop the wiggle of the male and female joins but it will certainlyHelp seal a bit if not completely! Let me know if this works for you.
Sent from my iPhone using Tapatalk
Post by: Chesto18 on November 27, 2018, 03:45:46 pm
I’d love the S3 option but ATM there are a fair few mods that would take priority.
I guess that airflow wouldn’t be as smooth with a silicone coupling but I’m wondering whether it would benefit overall anyway as the seal between pipe and intercooler would now be airtight. So whether a full seal is more beneficial than flow at this point.
I’ll measure up and see what my options are. The silicone reducers I’ve seen online aren’t expensive, so might be worth a go and see how I get on.
I suppose the best way to find out would be too try it. Like you said, an air tight seal is better than nothing.
Tell you what I tried for a proper tight fit (and convinced it works): wrap a few layers of PTFE tape in the boost pipe groove for boost seal. This pads out under the boost seal making it a little bigger in turn... a tighter fit / better seal (grease seal for easier fitting) and make sure the seal slides in nice and straight and doesn’t try flipping off the pipe. It’s worth a try mate! Don’t go too mad with the PTFE tape otherwise you’ll never get it in lol. Find the happy medium
Help seal a bit if not completely! Let me know if this works for you.
Sent from my iPhone using Tapatalk
That sounds like a plan! Will try that.
It’s only really that one connection that’s an issue. Other side of intercooler and the hose sides leading back to engine are fine. This one seems to not want to sit correctly even with replaced gaskets.
Post by: muff1991 on November 28, 2018, 04:24:10 pm
It’s allwaayyys this connection that’s crap.. trust!I’d love the S3 option but ATM there are a fair few mods that would take priority.
I guess that airflow wouldn’t be as smooth with a silicone coupling but I’m wondering whether it would benefit overall anyway as the seal between pipe and intercooler would now be airtight. So whether a full seal is more beneficial than flow at this point.
I’ll measure up and see what my options are. The silicone reducers I’ve seen online aren’t expensive, so might be worth a go and see how I get on.
I suppose the best way to find out would be too try it. Like you said, an air tight seal is better than nothing.
Tell you what I tried for a proper tight fit (and convinced it works): wrap a few layers of PTFE tape in the boost pipe groove for boost seal. This pads out under the boost seal making it a little bigger in turn... a tighter fit / better seal (grease seal for easier fitting) and make sure the seal slides in nice and straight and doesn’t try flipping off the pipe. It’s worth a try mate! Don’t go too mad with the PTFE tape otherwise you’ll never get it in lol. Find the happy medium
Help seal a bit if not completely! Let me know if this works for you.
Sent from my iPhone using Tapatalk
That sounds like a plan! Will try that.
It’s only really that one connection that’s an issue. Other side of intercooler and the hose sides leading back to engine are fine. This one seems to not want to sit correctly even with replaced gaskets.
Sent from my iPhone using Tapatalk
Post by: pudding on November 29, 2018, 06:07:43 pm
(https://cdn.aws.toolstation.com/images/141020-UK/800/44852.jpg)
(https://cdn.aws.toolstation.com/images/141020-UK/800/73415.jpg)
(https://cdn.aws.toolstation.com/images/141020-UK/800/62770.jpg)
Post by: Chesto18 on November 30, 2018, 08:44:25 am
On inspection the hose was again around 1cm away from flush and oil dripping out. And once reseated (as has happened every time I’ve reseated this connection) the car felt immediately more responsive at lower revs and generally torquier.
Hopefully this will work otherwise I need a permanent solution.
Post by: muff1991 on November 30, 2018, 10:33:10 am
Post by: pudding on November 30, 2018, 02:39:26 pm
I don't know what other priorities you have but £270 is not unreasonable to fix this problem permanently - https://www.darksidedevelopments.co.uk/products/audi-s3-intercooler-with-alloy-end-tanks-for-mk5-mk6-platform.html
Post by: colesey on November 30, 2018, 02:52:32 pm
Post by: pudding on November 30, 2018, 03:11:00 pm
Post by: muff1991 on November 30, 2018, 03:13:09 pm
https://www.ebay.co.uk/itm/NEW-LARGE-UPGRADED-ALLOY-FRONT-MOUNT-INTERCOOLER-KIT-FOR-AUDI-A3-VW-GOLF-PASSAT/322634310826?fits=Car+Make%3AAudi%7CCars+Type%3AS3+quattro&epid=2171810844&hash=item4b1e80e4aa:g:JKoAAOSw2n5ZhJtc:rk:3:pf:0
@Dave aka (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=27661) got this for his K04 build.. it looks a real good quality!
Post by: pudding on November 30, 2018, 03:22:32 pm
Post by: muff1991 on November 30, 2018, 03:32:45 pm
I'm not to sure if I want to get this exact one for my K03 though, as surely the turbo would need to work harder to fill the larger system.. longer spools etc
Post by: pudding on November 30, 2018, 03:54:08 pm
Post by: Chesto18 on November 30, 2018, 11:12:46 pm
PTFE won't hold up for long. I looked into a mechanical way of stopping the hose from pulling out but there's nothing to grip onto.
I don't know what other priorities you have but £270 is not unreasonable to fix this problem permanently - https://www.darksidedevelopments.co.uk/products/audi-s3-intercooler-with-alloy-end-tanks-for-mk5-mk6-platform.html
It’s not unreasonable but I was hoping to spend the next £300 on a remap. It does make a big difference to the tightness of the boost when that connection is properly seated though.
I’ve seen a few eBay cheap Chinese intercoolers that look like they might do a job.
At the moment though I still have a bad knocking front the drivers footwell under braking (hoping it’s not the steering rack) which is a priority, and I was hoping to get the pre-cat drilled out at the same time. That was going to be the next big spend.
Never ends!