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  1. #1
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    HELP! I snapped my nipple off.....

    ......the intake manifold.

    As the repair of my car was nearing with the parts ordered from audi for the PCV breather hoses etc, i decided to be extra and do the N249 bypass as all the bits were out and the access was easy,

    In the ongoing war with the clamp clips or whatever you wana call them, this one was really awkward and would not come off, i got carried away with a pair of pliers without thinking and snapped the nipple off from under the manifold where the hose connects for the BOV!

    What on earth am i supposed to do now??? please help.........
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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  3. #2
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    i doubt youll ever reattach it successfully

    youll have to work out a way of blanking it permanently

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    i was thinking jb weld? or is there a way to block it so i don't need it?

    or... what if i flush it where its snapped and force a tight fit tubing into it?

    Hope i dont have to end up buying a manifold.

    im soo gutted!
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

  5. #4
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    Mate, that's just unlucky, second mani's can be bought for about 40 if you look hard enough.
    Driving the most secretive S3 on ASN

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    id carefully file it flush then try and find a grommet that will fit in/over the hole and bond it into place

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    where can i find a grommet with a nipple thingy on it? or will it work if i bond a rubber/metal grommet or washer onto the manifold then bond the pipe into that?
    Last edited by zseth; 26th July 2010 at 17:19.
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    you actually want to get hold of something like this mate

    http://www.micromatic.com/draft-keg-...-pid-617C.html

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    Quote Originally Posted by quattro1 View Post
    you actually want to get hold of something like this mate

    http://www.micromatic.com/draft-keg-...-pid-617C.html
    thats what i was thinking, i'd have to get the threads drilled in the manifold though right? unless i can find same part with smooth end instead of threads and bond it in
    Last edited by zseth; 26th July 2010 at 17:32.
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    ......the intake manifold.

    As the repair of my car was nearing with the parts ordered from audi for the PCV breather hoses etc, i decided to be extra and do the N249 bypass as all the bits were out and the access was easy,

    In the ongoing war with the clamp clips or whatever you wana call them, this one was really awkward and would not come off, i got carried away with a pair of pliers without thinking and snapped the nipple off from under the manifold where the hose connects for the BOV!

    What on earth am i supposed to do now??? please help.........
    If I were you, I'd get someone (or you) to put a blob of weld over it to blank it and pressure test it to make sure it doesn't leak.

    Then T into the pipe coming from the one nipple and use that one nipple for both feeds.

    Bobs your aunt - fixed. However, very important to make sure that the T you put in doesn't leak, s can affect the fuel pressure regulator, meaning less fuel than needed. Will be fine as long as it doesn't leak.
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    Quote Originally Posted by Welly View Post
    If I were you, I'd get someone (or you) to put a blob of weld over it to blank it and pressure test it to make sure it doesn't leak.

    Then T into the pipe coming from the one nipple and use that one nipple for both feeds.

    Bobs your aunt - fixed. However, very important to make sure that the T you put in doesn't leak, s can affect the fuel pressure regulator, meaning less fuel than needed. Will be fine as long as it doesn't leak.
    Sounds like a genius plan mate!

    will it not restrict the work of the other hose? although its a braided hose il replace it with samco silicone hose, i think il seal the hole with jb weld or steel weld (cold welding that comes in two tubes to mix then apply)

    Atleast it will get me back on the road..... i didnt really want to go down the route of taking the manifold off and getting it thhreaded etc as iv had enough of DIY for now. just want it sorted and back on the road.
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    Sounds like a genius plan mate!

    will it not restrict the work of the other hose? although its a braided hose il replace it with samco silicone hose, i think il seal the hole with jb weld or steel weld (cold welding that comes in two tubes to mix then apply)

    Atleast it will get me back on the road..... i didnt really want to go down the route of taking the manifold off and getting it thhreaded etc as iv had enough of DIY for now. just want it sorted and back on the road.
    Nope, will work just fine. It's boost pressure at the end of the day, it will just fill both hoses. Thats how a boost gauge works for example, you T into either the FPR pipe or the DV pipe and that works just fine, and causes no problems.
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    thanks welly, and thanks for all replies, il see if i can find a female hose barb like this http://www.chicompany.net/images/Fem..._05b01-109.jpg and cold weld it over the hole in manifold and if not il just cold weld the hole shut and T off from the other hose.

    Hopefully car should be running great again tomorrow!

    cant wait and will keep the post updated
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    thanks welly, and thanks for all replies, il see if i can find a female hose barb like this http://www.chicompany.net/images/Fem..._05b01-109.jpg and cold weld it over the hole in manifold and if not il just cold weld the hole shut and T off from the other hose.

    Hopefully car should be running great again tomorrow!

    cant wait and will keep the post updated
    I'm sure either way will be fine, although would be suspicious as to how well that hose barb would take, and how long it would stay on. Still, don't know until you try.
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    ok guys, i got back from work like and anxious kid and got straight to the job, fitted all the new parts with jubilee clips and having liquid welded the hole where the nipple snapped off in the morning, i took time to do the job properly, all the bits are back on now, im missing one jubilee clip which i will have to get tomorrow and upon starting the engine there was no hunting in the idle etc, started up straight away and sounds fine,

    so.... cant wait till tomorrow now to get that clip on and take the car for a spin!

    N249 valve has been bypassed as well so looking forward to the difference,

    if it hisses again i will not be a happy bunny!
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    ok guys, i got back from work like and anxious kid and got straight to the job, fitted all the new parts with jubilee clips and having liquid welded the hole where the nipple snapped off in the morning, i took time to do the job properly, all the bits are back on now, im missing one jubilee clip which i will have to get tomorrow and upon starting the engine there was no hunting in the idle etc, started up straight away and sounds fine,

    so.... cant wait till tomorrow now to get that clip on and take the car for a spin!

    N249 valve has been bypassed as well so looking forward to the difference,

    if it hisses again i will not be a happy bunny!
    Which way did you go in the end dude?
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  17. #16
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    i wouldnt be able to wait that long!! i love the post bodge test drive lol

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    Quote Originally Posted by Matt82 View Post
    i wouldnt be able to wait that long!! i love the post bodge test drive lol
    Indeed - it fun seeing how long the cable tie lasts....
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    Quote Originally Posted by Welly View Post
    Which way did you go in the end dude?
    Dude, i went with your brains this time as mine made the nipple break off lol

    Just took it for a test drive and im not sure with the results, hissing is still there in high gears and full throttle which leads me to suspect the BOV is dumping too quick!

    going to check it once engine has cooled down a bit
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    Dude, i went with your brains this time as mine made the nipple break off lol

    Just took it for a test drive and im not sure with the results, hissing is still there in high gears and full throttle which leads me to suspect the BOV is dumping too quick!

    going to check it once engine has cooled down a bit
    You sure it's the DV? It could be a boost leak, higher gears produce a bigger request on the turbo for boost, especially when putting your foot down from 50 MPH in 5th/6th for example.

    What sort of DV are you running, stock or other?
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  21. #20
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    At this point Welly remembers that you have a Boost Leak thread open at the moment.... LOL.
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  22. #21
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    ive lost track in this thread

    did you just blank off the snapped nipple?

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    Quote Originally Posted by Matt82 View Post
    did you just blank off the snapped nipple?
    Yeah, I think that's what's gone down.

    Harry didn't have any stubs, could of got some overnight from Japan though - bit costly.
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  24. #23
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    ONFJ(tm) is the only way, i have to use that service so often ive had to trademark the abreviation .

  25. #24
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    Quote Originally Posted by Matt82 View Post
    ONFJ(tm) is the only way, i have to use that service so often ive had to trademark the abreviation .
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    "Marriage is like a coffin and each kid is another nail."
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    Quote Originally Posted by Matt82 View Post
    ive lost track in this thread

    did you just blank off the snapped nipple?
    sorry mate, too much going on lol,

    thats right i just blanked off the snapped nipple
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by Welly View Post
    You sure it's the DV? It could be a boost leak, higher gears produce a bigger request on the turbo for boost, especially when putting your foot down from 50 MPH in 5th/6th for example.

    What sort of DV are you running, stock or other?
    im running a stock DV, tested it and it releases a little bit with finger on nozzle, then releases fully with finger off.
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    WELLY - we have cracked it! your brains and my cuts and scrapes, it was a split hose!!! the ones that comes from the BOV to the big Turbo pipe past the N249 Valve!!!! it was split under the jubilee clip and torn along the jubilee clip!

    cut it back a bit and screwed it back on took it for a spin and all sorted.......will update the boost leak thread now

    thanks mate!
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    tbh id run a new vac line from the dv, back to the fuel pressure reg.

    put a t in and then run it to your remaining good nipple and then be a WINNER

  30. #29
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    Quote Originally Posted by zseth View Post
    WELLY - we have cracked it! your brains and my cuts and scrapes, it was a split hose!!! the ones that comes from the BOV to the big Turbo pipe past the N249 Valve!!!! it was split under the jubilee clip and torn along the jubilee clip!

    cut it back a bit and screwed it back on took it for a spin and all sorted.......will update the boost leak thread now

    thanks mate!
    Sweet, certainly sounded like a boost leak problem.

    Glad you found that, let me know results tomorrow.

    Nice work
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    hi welly, took the car out on the open roads today and not much hissing at all, although i still suspect the DV is dumping boost as it lets off steam too early!

    need to find a nearby member and try their DV
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    or get your own dv off and test it? where abouts are you based?

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    Quote Originally Posted by Matt82 View Post
    or get your own dv off and test it? where abouts are you based?
    hi matt, im in ilford, essex

    i tested it, it drops a few mm and stays till i release my finger off the top.
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

  34. #33
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    Quote Originally Posted by zseth View Post
    hi matt, im in ilford, essex

    i tested it, it drops a few mm and stays till i release my finger off the top.
    Hmmmm, any idea how old it is?

    In all seriousness, for the 30ish it will cost, I'd change it for another stock DV for testing purposes.

    To be fair, when they go, they tend to go completely. The idea is that the pressure from the inlet manifold forces (through the pipe to the top) the internals to stay shut. When you come off the throttle, there is a vacuum in the inlet manifold as the throttle body closes, which then sucks the DV open to release boost pressure. There isn't that much to go wrong with them.

    Get a new one for testing.
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    ive got a fella coming down from chigwell after work tonight. he says his feels like its loosing boost and that if feels down on power

    for a laugh im going to gtech it before and after the work to see what can be gained in a couple hours and ill post back and let you know.

    his is an a3 aum. gonna go over the inlet system from start to finish then pressure test it all. ive only done servicing on his in the past (his is the one we found bits of broken dipstick tube in the oil pump pick up!) so i know its now in a good condition service wise, now were gonna start getting it completely up to scratch

    he is coming along on sunday to the drag racing thing so he wants as much of a chance as he can get against my tiny turbod mk4

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    Quote Originally Posted by Matt82 View Post
    ive got a fella coming down from chigwell after work tonight. he says his feels like its loosing boost and that if feels down on power

    for a laugh im going to gtech it before and after the work to see what can be gained in a couple hours and ill post back and let you know.

    his is an a3 aum. gonna go over the inlet system from start to finish then pressure test it all. ive only done servicing on his in the past (his is the one we found bits of broken dipstick tube in the oil pump pick up!) so i know its now in a good condition service wise, now were gonna start getting it completely up to scratch

    he is coming along on sunday to the drag racing thing so he wants as much of a chance as he can get against my tiny turbod mk4
    Thanks matt, let me know how it goes, im going to check a few other hoses tomorrow that are on the back side of the engine around the big turbo pipe, then il see if my mates Y plate 1.8T A4 has the same DV and il try it on mine
    2001 AMK S3, Black, Lowered, 18" RS4 Diamond cut and Black Polished Alloys

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    Quote Originally Posted by zseth View Post
    Thanks matt, let me know how it goes, im going to check a few other hoses tomorrow that are on the back side of the engine around the big turbo pipe, then il see if my mates Y plate 1.8T A4 has the same DV and il try it on mine
    It should do, or at least be good enough for testing purposes.
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    "Marriage is like a coffin and each kid is another nail."
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