Audizine - An Automotive Enthusiast Community

Results 1 to 27 of 27
  1. #1
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Manifold to turbo exhaust leak

    Guest-only advertisement. Register or Log In now!
    The area around my turbo smells like uncatalyzed exhaust. My last k04 had no smell at all... I reused the old gasket and exhast bolts between manifold and turbo since they were only 2 years and 20k miles old. Could that be causing this? All I can think to do is put a new gasket on, I tightened the crap out of it already. So it's tight as it can go right now. It's also making a bit of a *thhhhhh* sound on that side when I try to boost. And it's also not as boosty as the old k04, it does that intermittent on/off boost thing. Like it builds and drops.

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  2. #2
    Veteran Member Three Rings
    Join Date
    Sep 05 2013
    AZ Member #
    122596
    Location
    Ottawa, Ontario

    I would just try a new gasket. I think the rule is, if you remove a gasket you should replace it even if it's not old. I believe they all crush differently when applied. Gaskets are cheap anyways lol

  3. #3
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Can i use 2 of these gaskets instead of 1?

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  4. #4
    Veteran Member Four Rings old guy's Avatar
    Join Date
    Dec 28 2006
    AZ Member #
    14483
    My Garage
    '13 A5, '24 Tiguan SEL R-Line
    Location
    Western Maryland

    Quote Originally Posted by jacobsen View Post
    Can i use 2 of these gaskets instead of 1?
    Why do you feel the need to use two gaskets? As long as the mating surfaces are in good shape one gasket should suffice.
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  5. #5
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Quote Originally Posted by old guy View Post
    Why do you feel the need to use two gaskets? As long as the mating surfaces are in good shape one gasket should suffice.
    I thought I could reuse my old gasket but apparently not since it's leaking, you can't really see it but you can certainly smell it. I don't know, I just thought it might be better than one. I don't want to have to do this again.

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  6. #6
    Veteran Member Four Rings old guy's Avatar
    Join Date
    Dec 28 2006
    AZ Member #
    14483
    My Garage
    '13 A5, '24 Tiguan SEL R-Line
    Location
    Western Maryland

    As stated, as long as the mating surfaces are good one gasket should be fine
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  7. #7
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Alrighty, I still wonder if two isn't better than one Doublemint gum

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  8. #8
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Barely anything happens when I step on the gas, either I have more than an exhaust leak or a big exhaust keak.

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  9. #9
    Veteran Member Four Rings Furly's Avatar
    Join Date
    Dec 19 2013
    AZ Member #
    136650
    Location
    Bay Area, CA

    It's a crush gasket. Would you reuse a head gasket ? Never reuse gaskets.
    And don't buy the shitty thin ones from ATP. They're garbage. Make sure you tighten everything down evenly and re-check it after a few heat cycles. GL
    Audi Club Bay Area

  10. #10
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    P0299 and P2181

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  11. #11
    Veteran Member Four Rings CyberPMG's Avatar
    Join Date
    Feb 23 2004
    AZ Member #
    806
    My Garage
    2004 A4 1.8T Ultrasport 6MQ
    Location
    Stow, OH

    P0299 is an under-boost code - Did you replace the gaskets with new ones? Do not double up on gaskets. Also check for any vacuum leaks. Put it on a lift and see if there are any other leaks in the exhaust.

    P2181 is a generic coolant code - Could be a faulty thermostat or coolant sensor.
    USP CLUB MEMBER #34

    2004 A4 1.8T USP - GT2871R Eliminator - Motoza program - Over 375k miles!
    2015 S5 - Sepang Blue - 6spd w/ Sport Diff - stock(ish)

  12. #12
    Veteran Member Four Rings
    Join Date
    Feb 12 2008
    AZ Member #
    25194
    Location
    Michigan

    Any broken studs on the manifold itself?

  13. #13
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    I reinstalled a new turbo inlet gasket today. However the heavy smell of uncatalyzed exhaust is still happening. I did not spot any leaks in the exhaust manifold or any cracks. I'm beginning to suspect that the exhaust is leaking where the chra and exhaust side meet. I don't have any proof of anything but I've never had any exhaust smell coming from the turbo before and the only difference here is a new turbo. The codes have not returned so far, I've only driven around the neighborhood so lets just see.

    Sent from my SM-G920V using Tapatalk
    Last edited by jacobsen; 03-09-2016 at 08:11 PM.
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  14. #14
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  15. #15
    Veteran Member Three Rings
    Join Date
    Sep 05 2013
    AZ Member #
    122596
    Location
    Ottawa, Ontario

    I dont know if it's just me but at around 1:05 it almost sounds like the turbo to cat gasket is leaking...

  16. #16
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Update: I drove about 15 miles on the freeway and I noticed the car definitely runs and accelerates better. I removed the foam from the airbox and I'm hearing thshh! Sound from it when I accelerate? The exhaust smell is still happening, at the 1:05 mark the camera is right on the turbo exhaust to high-flow cat gasket. That's also a brand new gasket, I tightened it a lot when I put it on. Can over-tightening it cause a leak? It's got a ceramic coating. No codes yet.

    Sent from my SM-G920V using Tapatalk
    Last edited by jacobsen; 03-09-2016 at 10:41 PM.
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  17. #17
    Established Member Two Rings Noma12vA4's Avatar
    Join Date
    Jan 14 2011
    AZ Member #
    69504
    My Garage
    b7 a4 2.0tQ S line - stock
    Location
    Northbay/CA

    Yea i see the same ^, looks like the gasket is blown and slightly poking out. Try having a partner rev it a bit and feel for air poofing out from there.



    '04 A4 1.8t USP 6-speed : Revo GT2871r
    '04 A4 1.8t USP 6-speed : APR Stage 1+ Don't let friends drive your car
    ´99.5 A4Q 2.8 30v: sold
    96 A4Q 2.8 12v: Gone but never forgotten

    //Auto Union Bay Area

  18. #18
    Veteran Member Four Rings diagnosticator's Avatar
    Join Date
    Aug 26 2005
    AZ Member #
    7741
    Location
    Seattle, WA

    Quote Originally Posted by jacobsen View Post
    The area around my turbo smells like uncatalyzed exhaust. My last k04 had no smell at all... I reused the old gasket and exhast bolts between manifold and turbo since they were only 2 years and 20k miles old. Could that be causing this? All I can think to do is put a new gasket on, I tightened the crap out of it already. So it's tight as it can go right now. It's also making a bit of a *thhhhhh* sound on that side when I try to boost. And it's also not as boosty as the old k04, it does that intermittent on/off boost thing. Like it builds and drops.

    Sent from my SM-G920V using Tapatalk
    Using no gasket is the most reliable setup. In order for this to work, the turbo and the exhaust manifold must me milled flat, or surfaced flat using a natural stone floor tile that is finished smooth and shiny, with a piece of 200 grit wet/dry sand paper glued to the tile surface using spray adhesive. Surface the two mating surfaces on the flat plate flooded with water so that there is no gap anywhere between the turbo and the exhaust manifold. Use machinist layout blueing spray on the two surfaces to check for even contact across the mating areas. With no gasket, the joint can't loosen due to the gasket compressing over time and there is nothing to fail and leak.
    Vorsprung durch Technik

  19. #19
    Veteran Member Four Rings old guy's Avatar
    Join Date
    Dec 28 2006
    AZ Member #
    14483
    My Garage
    '13 A5, '24 Tiguan SEL R-Line
    Location
    Western Maryland

    Also check and make sure that your combi valve isn't loose or cracked. That would create an open pathway to the exhaust stream.
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  20. #20
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    I replaced the gaskets and still have the exhaust leak and heavy stink. The turbo was boosting we'll until yesterday I drove to madison 2 days ago. Now there is no boost, it barely pulls at all, n75 hoses appear good. I turned off the car and woke up to find the motor had gone lame. No codes. Is it possible for the chra to leak exhaust?

    Sent from my SM-G920V using Tapatalk
    Last edited by jacobsen; 03-20-2016 at 06:10 PM.
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  21. #21
    Veteran Member Four Rings CyberPMG's Avatar
    Join Date
    Feb 23 2004
    AZ Member #
    806
    My Garage
    2004 A4 1.8T Ultrasport 6MQ
    Location
    Stow, OH

    Check the manifold for signs of any cracks or holes in it. Also check the flex pipe in the exhaust to make sure that's not crumbling. Do you still have your catalytic converter? If so, how old and how many miles on it? Check the gasket between the turbo and the cat. Check the cat. Check the gasket between the cat and the downpipe.
    USP CLUB MEMBER #34

    2004 A4 1.8T USP - GT2871R Eliminator - Motoza program - Over 375k miles!
    2015 S5 - Sepang Blue - 6spd w/ Sport Diff - stock(ish)

  22. #22
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    I don't see any visible cracks in the manifold, the flex pipe is good, I have a high-flow cat, it's about 4 years old, it has about 50,000 miles on it. The turbo exit to cat gasket this is what I just replaced as well as the turbo exhaust inlet. The downpipe two catalytic gasket seems okay. The problem is it's so hot in that area, it's not obvious where the leak is coming from.

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  23. #23
    Veteran Member Four Rings CyberPMG's Avatar
    Join Date
    Feb 23 2004
    AZ Member #
    806
    My Garage
    2004 A4 1.8T Ultrasport 6MQ
    Location
    Stow, OH

    If you're using a high flow exhaust manifold like the ones from ATP, 034, etc., those are known to crack. Don't just look at it when attached from above. The cracks/holes can also appear underneath and in the area where the runners merge together. I would recommend staying away from those manifolds and either stick with an OEM manifold or look into a BEX manifold (OEM manifold for the BEX 1.8t motor that was offered in Europe). The BEX manifold is stronger and offers slightly more exhaust flow than stock, but has the strength to last longer than high flow manifolds.

    With a HFC, it can have an exhaust smell just like a test pipe. You may want to peer inside and make sure all cells are in place. I've had a HFC for 4-5 years and found some of the cells in the center were gone requiring a replacement of the HFC.
    USP CLUB MEMBER #34

    2004 A4 1.8T USP - GT2871R Eliminator - Motoza program - Over 375k miles!
    2015 S5 - Sepang Blue - 6spd w/ Sport Diff - stock(ish)

  24. #24
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    The cat is good, I took a video of it and posted it not long ago. I'm using the original manifold. Now I'm getting these codes P0171. P0234 I'm starting to hate my Audi

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

  25. #25
    Veteran Member Four Rings CyberPMG's Avatar
    Join Date
    Feb 23 2004
    AZ Member #
    806
    My Garage
    2004 A4 1.8T Ultrasport 6MQ
    Location
    Stow, OH

    With the overboost error code (P0234) the N75 may need replacing. For the lean code (P0171) try cleaning the MAF sensor.
    USP CLUB MEMBER #34

    2004 A4 1.8T USP - GT2871R Eliminator - Motoza program - Over 375k miles!
    2015 S5 - Sepang Blue - 6spd w/ Sport Diff - stock(ish)

  26. #26
    Veteran Member Four Rings Pr1ce's Avatar
    Join Date
    Aug 11 2014
    AZ Member #
    273587
    My Garage
    13' prestige
    Location
    Kissimmee

    Quote Originally Posted by diagnosticator View Post
    Using no gasket is the most reliable setup. In order for this to work, the turbo and the exhaust manifold must me milled flat, or surfaced flat using a natural stone floor tile that is finished smooth and shiny, with a piece of 200 grit wet/dry sand paper glued to the tile surface using spray adhesive. Surface the two mating surfaces on the flat plate flooded with water so that there is no gap anywhere between the turbo and the exhaust manifold. Use machinist layout blueing spray on the two surfaces to check for even contact across the mating areas. With no gasket, the joint can't loosen due to the gasket compressing over time and there is nothing to fail and leak.
    I had a similar issue at OP with the gasket and tried multiple ones... Only solution was no gasket and it worked flawlessly.

  27. #27
    Veteran Member Four Rings
    Join Date
    Aug 19 2013
    AZ Member #
    121375
    Location
    minnesota

    Quote Originally Posted by Pr1ce View Post
    I had a similar issue at OP with the gasket and tried multiple ones... Only solution was no gasket and it worked flawlessly.
    With same motor? Did you do the sanding thing?

    Sent from my SM-G920V using Tapatalk
    APR exhaust, HFC, 225 injectors, APR II program, KO4, South Bend II endurance clutch and SMFW, Forge Tip+piping, Apikol SMIC, Stern motor+trans mounts, Stern Snub, 034 street density arms, Hotchkis sway bars, Lemforter links, Bilstein B8, B7 S4 calipers, powerstop braided lines, Centric drilled rotors, PowerStop Carbon Fiber pads, Timken bearings, Gates racing timing belt, DENSO IQ01-27 plugs, R8 coils, Motul Xcess 5w40, MANN 950/4 filter, gear300, CHF202, Motul RBF 660.

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  


    © 2001-2024 Audizine, Audizine.com, and Driverzines.com
    Audizine is an independently owned and operated automotive enthusiast community and news website.
    Audi and the Audi logo(s) are copyright/trademark Audi AG. Audizine is not endorsed by or affiliated with Audi AG.