Rattle like noise around exhaust manifold area f21 stage 3 Aeb

[PsorianoPre99A4]

I have a 99aeb stage 3 630cc tune with a f21, just got it used recently. Running great until the other day starting hearing this loud rattle noise on acceleration and slightly on idle. I think it's a possible exhaust leak? Cam tensioner? Valve clatter? Turbo just louder? Do I need to install my fmic? I also see a small amount of oil in back side of engine that builds up around the heat shield. I did change the valve cover about 6k ago.
Any thoughts? However, Car boosts and drive fine, just has that annoying noise on acceleration now..here is a video




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[Davdraco1]

Sounds like an exhaust leak to me.

[PsorianoPre99A4]

Yup that's what it is.. I took my heat shield off and stuck my hand down there and a tissue around the 3cyl and felt hot air. There's no way to fix it unless I take the whole turbo off right?


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[Davdraco1]

Yea, the turbo manifold has studs and need to slide off before the gasket comes only.

[MetalMan]

Did you verify the turbo mounting bolts/studs are still tight? Back in the day I had major issues with turbo bolts/studs backing out on my FT setup. It's resolved now, of course.

[andyrew]

I've had the exhaust manifold studs loosten up on me. Check those as well.

[PsorianoPre99A4]

The bolts from the turbo to testpipe are fine. I can't reach the other ones on the exhaust manifold. It's too tight of a space even with the heat shield off.


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[PsorianoPre99A4]

You guys have any suggestions on what to use to tighten them? The f21 manifold is rather big to fit any open wrenches or standard sockets to fit..

I had a shop quote me about $330 to do the job. With parts. Also what gasket you all recommend I use to prevent this?


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[MetalMan]

What about the bolts/studs that mount the turbo to the exhaust manifold?

Good info on exhaust mani install:
http://www.audizine.com/forum/showth...1#post10555125

The jist is to use 034's 10mm-head nuts (on the 8 hardest-to-access spots), a 10mm crow's-foot wrench, and a wobble extension. Can also possibly use an offset box wrench but that will have less flexibility.

[andyrew]

Your lucky its not an APR manifold.... There are 4 bolts that sockets will fit on. The rest have to be done with wrenches, or custom made wrenches/wrench sockets.

[MetalMan]

Your lucky its not an APR manifold.... There are 4 bolts that sockets will fit on. The rest have to be done with wrenches, or custom made wrenches/wrench sockets.

IMO, APR manifold is easier than FT manifold . I've done both.

[PsorianoPre99A4]

IMO, APR manifold is easier than FT manifold . I've done both.

What exhaust manifold gasket do you recommend with the FT manifold? I bought the kit from frankenturbo, and it didn't work out for me or the "Audi Mastertech" who installed it 6 monthes ago didn't do it correctly. Or I should have re-tightened the exhaust mani bolts earlier?

And you say to use 034 10mm head nuts (are they locking nuts)? I'm considering just doing this job myself this time. Any tips to do this?

[MetalMan]

What exhaust manifold gasket do you recommend with the FT manifold? I bought the kit from frankenturbo, and it didn't work out for me or the "Audi Mastertech" who installed it 6 monthes ago didn't do it correctly. Or I should have re-tightened the exhaust mani bolts earlier?

And you say to use 034 10mm head nuts (are they locking nuts)? I'm considering just doing this job myself this time. Any tips to do this?

Gasket doesn't really matter, but I use only Victor Reinz or Elring.
If you bought the hardware install kit from FrankenTurbo, it may have already come with the 10mm-head locknuts.

Many installation tips are available in Old Guy's thread I linked to above. I've also posted throughout Audizine various tips. Just do some searching and you may come across them.

BTW, you never answered this question:

What about the bolts/studs that mount the turbo to the exhaust manifold?

[PsorianoPre99A4]

Gasket doesn't really matter, but I use only Victor Reinz or Elring.
If you bought the hardware install kit from FrankenTurbo, it may have already come with the 10mm-head locknuts.

Many installation tips are available in Old Guy's thread I linked to above. I've also posted throughout Audizine various tips. Just do some searching and you may come across them.

BTW, you never answered this question:

Ok Yeah they are the copper ones installed right now, however, I am missing one closest to the front.

As for the 3 bolts/studs holding the turbo to the EM, they are solid and haven't moved ( I have that turbo locking flange thing on it with the bolts holding it down). Was that what you were talking about?

[MetalMan]

Ok Yeah they are the copper ones installed right now, however, I am missing one closest to the front.

Copper color is the same whether they're 10mm head, 12mm head, or 13mm head.

As for the 3 bolts/studs holding the turbo to the EM, they are solid and haven't moved ( I have that turbo locking flange thing on it with the bolts holding it down). Was that what you were talking about?

Yeah that's it. Just wanted to make sure.

[PsorianoPre99A4]

Copper color is the same whether they're 10mm head, 12mm head, or 13mm head.



Yeah that's it. Just wanted to make sure.

Ah got ya. Yeah I put my wrench up to the ones on the outside. They're 10mm. Yeah I'm going to do this job myself I decided. Whats the easier way to take the turbo out? From under or from the engine bay?

[MetalMan]

From the top. No way it's coming out from under the car. I highly advise putting the front end in service position (since you need to drain coolant anyways to pull the turbo).

[PsorianoPre99A4]

From the top. No way it's coming out from under the car. I highly advise putting the front end in service position (since you need to drain coolant anyways to pull the turbo).

The reason I ask, I heard some people drop it from where the AC compressor is. Is it necessary to put in service position, whats the main purpose? I can drain the coolant with the front end still on.

[MetalMan]

I've never heard of anyone dropping the turbo from the AC compressor area. However it is quite necessary (IMO) to drop the AC compressor to gain better access to the turbo support bracket and oil drain line.

Pulling the turbo and manifold is a lot easier with the front end removed (or in service position). It grants better access to the manifold and coolant drain line at the block. Also with the front end off/service position you can more easily install the DV and TIP, especially if you use the stock air box (like I do, with a 3" MAF housing).
Also I like the front end out of the way so I'm not leaning over it while I work. Makes for more comfortable working positions.