update on problems/codes

Johnny Alpha johnnyalpha at beeb.net
Tue May 21 22:28:37 EDT 2002

I made the leak testing tool too. I would not have found all leaking
components using a visual inspection and further tightening of hose
clamps would have made it worse. I needed to replace:

1)Turbo Inlet Hose (rotten at turbo connection)
2)Michelin man hose (split, caused by over-tightened clamp)
3)Both engine breather hoses (rotten from oil contact)
4)Intercooler o-ring
5)Oil filler cap (genuine about $5!)
6)Dip-stick o-ring

I replaced all the small-bore hoses too, to be on the safe side & put
clamps on where they had been missing.

Just one further thing, if you are going to test to 20psi, disconnect
the MAP sensor first to protect from damage!


-----Original Message-----
From: 200q20v-admin at audifans.com [mailto:200q20v-admin at audifans.com]On
Behalf Of Phil Rose
Sent: 21 May 2002 18:24
To: Mike Miller
Cc: 200q20V mailing list
Subject: Re: update on problems/codes

>Here is the leak tester I made several yrs ago - works great - about $7 to
>build as I recall. Pressurize to 20 psi max. I've posted this serveral
>times. I'd loan it out but shipping would likely cost more than the tester.

Yeh, that's the ticket! Do you just use a tire gauge to check for
constant pressure?

Also, you mention releasing pressure with the oil-filler cap, and
that suggests another source of leakage. A couple of years ago I got
tired of the chronic oiliness on the valve cover near the cap, so at
a cost of about $1 an official Audi paper gasket (ordered from
Carlsen Audi) was placed atop the tired, 10-yr-old one on the cap.
Can't say it solved a boost problem, but it keeps any oil from
depositing on top of the cam cover.


>----- Original Message -----
>From: Phil Rose <pjrose at frontiernet.net>
>To: Dan Simoes <dans at audifans.com>
>Cc: 200q20V mailing list <200q20v at audifans.com>
>Sent: Tuesday, May 21, 2002 10:22 AM
>Subject: Re: update on problems/codes
>>  >Phil Rose wrote:
>>  >
>>  >>  Also I assume you've
>>  >>  double-checked all hoses and hose clamps, since the "bucking"
>>  >>  you mentioned is possibly from fuel cut-off caused by a hose "burp".
>>  >
>>  >That's an interesting theory.  How do you check hoses and clamps, other
>>  >than visually?
>>  Well, the glib answer is to keep tightening all clamps 'till the
>>  problem goes away. :-)
>>  As to non-visual checks for leaks and splits: Brett --a couple of
>>  years ago-- had decribed a device he put together for measuring
>>  intake-pressure leakage. I've been meaning to make something similar
>>  since it can save a lot of time hunting for problem spots. Involves
>>  simple some plumbing inserted at the entrance to the turbo intake
>>  hose. Of course you still need to track down the location(s) of the
>>  problem (audible hissing?) Brett, perhaps you can repost that?
>>  My "method" is just to tediously verify that every one of the intake
>>  system clamps--especially ones that I or others have fiddled with
>>  recently-- require "significant" tightening torque. I think boost
>>  problems will typically be from a rather loose clamp--not one that
>>  requires considerable effort to tighten further. And it's easy to
>>  overlook some "little fellers" like the hard-to-reach 1" clamp below
>>  the idle stabilizer valve.
>>  I once had the "burp" problem, which turned out to be the big clamp
>>  at the throttle body. I had inadvertantly left it still needing one
>>  or two full turns (*easy* ones) to  snug up. I think it's useful to
>>  get a "feel" for snugness by using a direct driver on the clamp
>>  screw--if possible. Using a ratchet handle is convenient and
>>  generates more torque, but you have to be rather careful not to
>>  overtighten (break?), although usually the only damage will be to the
>>  clamp itself, which is not a big deal, unless you can't locate a
>>  replacement.
>>  Phil
>>  --
>>  Phil Rose Rochester, NY USA
>>  '91 200q (130 Kmiles, Lago blue)
>>  '91 200q   (57 Kmiles, Tornado red)
>>  mailto:pjrose at frontiernet.net
>>  _______________________________________________
>>  200q20v mailing list
>>  200q20v at audifans.com
>>  http://www.audifans.com/mailman/listinfo/200q20v


Phil Rose
Rochester, NY
mailto:pjrose at frontiernet.net
200q20v mailing list
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