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Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Peter Warman <iframe src='https://members.boardhost.com/ukautotalk11/info/user=Peter+Warman' width='330' height='300' border=0 style='border:none;'> on April 14, 2011, 1:24 pm

Year of Manufacture *: 2000
Engine Size and Code *: APU (petrol)
( Optional ) Scanner Used: VCDS
( Optional) Fault Codes: Non

Customer had complained of no boost for about 6 months. It had been to Audi who code read (no codes) inspected all the hoses and changed and tightened a few hose clips, they told him that power wise it was correct for that model and that boost problems would bring up a fault code. He then spent months trying to find a solution on Google

I had this in on Tuesday and did a Smoke Test, I could see some smoke coming up from front left so pulled a few parts off to gain access

I could then clearly see a jet of smoke, sort of pinhole size from the end of a pipe on a plastic elbow, closer inspection showed no pin holes or cracks in pipes, no chaffing

So decided to strip all the pipes off

This is what I found

The hose had a split along the full length inside, but no visible damage outwardly. The smoke was coming up the split, despite the clip being tight (about 1 mm wide)

Made up a new hose and refitted, smoke tested, now no leaks and full boost back, customer over the moon

Goes to show a visual inspection is never enough no matter how thorough you are, Smoke Test is the only way

Peter

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Craig Smith <iframe src='https://members.boardhost.com/ukautotalk11/info/user=ukat3248' width='330' height='300' border=0 style='border:none;'> on April 15, 2011, 8:38 pm, in reply to "Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"

Could you please advise where I can get my hands on one of these smoke tester ??

Thanks
Craig

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by tony bickers <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT5143' width='330' height='300' border=0 style='border:none;'> on April 15, 2011, 9:11 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Tony Bickers

Hickley Valtone, Derek Edwards from Ilexa, got mine from Hickleys, about £750.

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Kevin Apps <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT2589' width='330' height='300' border=0 style='border:none;'> on April 15, 2011, 10:19 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Kevin Apps

Cgaig.
Or Teeside Auto Tech (thats who supplied mine)and V-tech, both sponsors here.
Kev.

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Craig Smith <iframe src='https://members.boardhost.com/ukautotalk11/info/user=ukat3248' width='330' height='300' border=0 style='border:none;'> on April 16, 2011, 1:08 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"

Thanks Guys I'll check them out as it would be a handy bit of kit !!

Craig

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Shaun Dale <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT2719' width='330' height='300' border=0 style='border:none;'> on April 16, 2011, 10:28 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"

Did not have the funds to buy one so on a couple of quiet days I made one. It is one of the most useful pieces of kit I have. Rather than make it mobile it is screwed to the wall by the compressor and has 5 metres of hose on it. Connect to car, air on, switch on, smoke, takes a couple of minutes,that's all.
Tested an Audi A4 1.8T yesterday. Three airleaks; insecure hose to turbo inlet, leaking vacuum valve on back of cam cover and leaking joint where the plastic elbow comes out of the crankcase breather. All found in one ten minute test, how would you do that any other way?
Shaun

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by dave hindmarsh <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT1214' width='330' height='300' border=0 style='border:none;'> on April 18, 2011, 10:03 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
David Hindmarsh

Shaun I would be very intrested to see what you made I have tried to make one but I am having a few problems

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Lee Mackintosh <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT1348' width='330' height='300' border=0 style='border:none;'> on April 19, 2011, 8:03 am, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Lee Mackintosh

Dave Hill also made a smoke tester and posted up some picutres of it so you may have to do a search to find them.

I think he used a secondary air blower from an Audi or similar to force the smoke through the sytem so didn't need the use of a compressor.

Dave's smoke machine

Posted by Peter Warman <iframe src='https://members.boardhost.com/ukautotalk11/info/user=Peter+Warman' width='330' height='300' border=0 style='border:none;'> on April 19, 2011, 8:35 am, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Peter Warman - Administrator

Dave's Smoke Machine

My smoke machine-Beware large photos!

Posted by Shaun Dale on April 26, 2011, 4:53 pm, in reply to "Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Message modified by board administrator April 27, 2011, 1:27 pm

Photos of my smoke machine attached.
The principle is simple and the result of what I gleaned from other web postings.
There is a bottle of baby oil with a wick in it, I used fiberglass rope which I bought years ago as a seal for the front glass of a Parkray solid fuel fire and had some left over. The wick is pushed up a suitably sized piece of antenna mast which in turn is held by a plastic cable gland. Around the wick is an element made from about 25 turns of stainless steel Mig welding wire (0.8mm). This all sits inside an old stainless and brass filter housing I rescued from some scrap many years ago, the power is fed in through a bolt with insulating washers both sides. Air is fed in on the right through a needle valve to control the flow then a pressure regulator and sticking out of the top is a pressure relief valve. No one can say that I cut any corners on safety there. The pressure relief is set to 1.2 bar and I set the pressure regulator between 0 and 1 bar. In all honesty I think the regulator is unnecessary but the pressure relief is a good idea, the last thing you want is to burst something on the car if there is no leak. The flow you need is very small just a tiny waft, not a strong blast. I only turn the needle valve on 1/2 a turn. Too much smoke and you cannot see where the leak actually is!
I originally fed it direct from a 12V battery but it proved too much for it. It looked good on test but as mentioned the flow is very low and the element then got too hot. I now feed it from a 12v transformer which is controlled via a power controller module, a domestic lamp dimmer will work to control power to the transformer. If you don’t feel competent to work with this sort of thing at mains voltages then use a bought power supply or run it from a battery, you could add more turns to the element to reduce the power.
I think a decent sized airline oiler would probably do the job as a housing, just take out the guts, fit a wick and change the oil. Add to that a needle valve of some sort to control the flow and a pressure relief and you’re away.
The universal connector system is self explanatory, or you could pay a fortune for something similar from one of those shops in Soho! I frequently connect at the MAF and have several blanking plugs as supplied with a new MAF with a hose union in the middle.

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by dave hindmarsh <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT1214' width='330' height='300' border=0 style='border:none;'> on May 2, 2011, 9:05 am, in reply to "Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
David Hindmarsh

Thanks dave and shaun for posting your photos of the smoke machines I like the idea of making my own

Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #

Posted by Dave Hill <iframe src='https://members.boardhost.com/ukautotalk11/info/user=UKAT2783' width='330' height='300' border=0 style='border:none;'> on February 15, 2012, 11:29 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"

Here is a short clip that shows my contraption in action...

http://www.youtube.com/watch?list=UUf5mGoHU019FUuCSxHOg3xw&feature=player_detailpage&v=jQ9qqkgEX7c

It will almost find a leak where there wasn't one before!

Dave's Video Reloaded

Posted by Peter Warman <iframe src='https://members.boardhost.com/ukautotalk11/info/user=Peter+Warman' width='330' height='300' border=0 style='border:none;'> on February 17, 2012, 12:49 pm, in reply to "Re: Audi A4 1.8T Sport APU 2000 - No boost, no codes - Fixed #"
Peter Warman - Administrator

Re: Dave's Video Reloaded

Posted by Peter Warman <iframe src='https://members.boardhost.com/ukautotalk11/info/user=Peter+Warman' width='330' height='300' border=0 style='border:none;'> on February 17, 2012, 12:53 pm, in reply to "Dave's Video Reloaded"
Peter Warman - Administrator

Also check out Dave's "Vehicle Troubshooter" article in next Months (March 2012) PMM magazine page 11 entitled "Pulley the other one"

Peter

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