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  1. #1
    L60N
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    I fink i broke my s3

    Hi guys,

    LoL, this is a funny one. Just been out for an extra spirited drive in my lunch hour.

    Set off for the open countryside, so the car had chance to warm up. As soon as it got to open roads i let rip in a major way... all's good at that point.

    I got stuck behind a wagon for a few mile so ended up crawling along, once i saw a length of open road i booted it to overtake. The car sounds VERY different at this point!

    All i can hear is a serious ripping noise coming from the exhaust. With the windows down it even drowns out the sound of the turbo!
    I slowed down to 20mph, and booted it again, the sound is still there. A loud ripping of forced air going through the exhaust.

    It does it in 1st,2nd,3rd,4th then slopes of in 5th,6th.

    Any ideas?

    Its sounds mental, but i Fink I broke it

    Im thinking that the exhaust has blown somewhere, or the turbos fooked...
    Last edited by L60N; 12th August 2008 at 12:54.

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  3. #2
    S3IZZO
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    I'd get your GIAC thingie out and stick it back to standard...repeat the process...if it's still there go to Audi.

  4. #3
    jonnyc's Avatar
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    Check the little arm which attaches to the valve on the exhaust (tail pipe), sounds like that has came off allowing the exhaust valve to stay open all the time, hence the noise..

    Dont worry..
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  5. #4
    L60N
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    I know what your saying Jordan, and I will

    But i cant see it suddenly stopping just because i put it back to standard. It wasnt doing before today and the maps been on over a week??
    Last edited by L60N; 12th August 2008 at 13:02.

  6. #5
    L60N
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    I Thought about that too Jonny as Alex told me about some flappy arm mod thing ages ago thats makes the exhaust louder sooner.

    It seems inkeeping with what im experiencing. Dont know where the flap is though
    Last edited by L60N; 12th August 2008 at 13:06.

  7. #6
    marriedblonde's Avatar
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    Quote Originally Posted by L60N View Post
    Dont know where the flap is though
    U'm guessing you never thought you'd admit that on the internet
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  8. #7
    DeckedS3's Avatar
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    Without hearing the noise.... Any chance the cat has corroded and split away? I did this in my R32 and it sounded terrible for a while till it blew it all out!

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  9. #8
    Gti Jazz Blue's Avatar
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    You sure you haven't just dropped a boost hose off or loose and you can hear the air escaping ? Does it do it off load without spining the turbo i.e. cruising ?
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  10. #9
    L60N
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    Quote Originally Posted by Gti Jazz Blue View Post
    You sure you haven't just dropped a boost hose off or loose and you can hear the air escaping ? Does it do it off load without spining the turbo i.e. cruising ?
    Nope, just when flooring it. Im going to investigate this flappy thing further, Its looking like the strongest contender, at least i hope lol ....

  11. #10
    Gti Jazz Blue's Avatar
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    I'd plumb for a loose boost hose if is does it when on WOT (wide open throttle) is it down on power on WOT ?
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  12. #11
    L60N
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    Quote Originally Posted by Gti Jazz Blue View Post
    I'd plumb for a loose boost hose if is does it when on WOT (wide open throttle) is it down on power on WOT ?
    It doesnt appear to be any less powerfull, just a lot louder!

    Ive read this thread, Exhaust Mod but no diagram. I'll have a look at it tonight.

    Maybe it got stuck with the wet weather?? lol, im clutching at straws now..

  13. #12
    jonnyc's Avatar
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    I have the standard exhaust in the garage, ill take some pics of what im talking about and explain what to look for, im pretty sure that will be the problem..

    Jonny
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  14. #13
    S3 Big Andy's Avatar
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    Sounds like an exhaust blowing, when they did the map did the change the engine mounts? if not the front flex can rip, but dont worry I have a spare you can have, well borrow/buy!
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  15. #14
    L60N
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    Quote Originally Posted by jonnyc View Post
    I have the standard exhaust in the garage, ill take some pics of what im talking about and explain what to look for, im pretty sure that will be the problem..

    Jonny
    Cheers Jonny!!

  16. #15
    L60N
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    It sounds like Alex's car (up front) but more so, listen at 17 secs:


  17. #16
    siu00adg's Avatar
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    Quote Originally Posted by L60N View Post
    It sounds like Alex's car (up front) but more so, listen at 17 secs:

    Sounds pretty good to me!

  18. #17
    L60N
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    It sounds a lot worse Alex!

    Download Sound clip 06.wav

  19. #18
    siu00adg's Avatar
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    Hmmm, did you check the solenoid arm on the exhaust? Sounds like there is a problem with the flap.

    Can you tell where the sounds is coming from?

  20. #19
    jonnyc's Avatar
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    Ok..

    Excuse the pics, pretty hard to show you what im on about but it should give you a good idea what to look for..

    The left hand tail pipe runs a butterfly valve which is operated by the solenoid attached near the tail pipes, over 3500rpm with certain throttle openings the exhaust valve will open to create more noise from the exhaust.

    This is how it should be, the exhaust flap in the closed position with the arm from the solenoid attached to the exhaust flap



    This is the exhaust flap in the open position, with the solenoid under vacuum it pulls the exhaust flap upwards and opens up for more noise (on throttle over 3500rpm)



    This is a pic of the arm from the solenoid no longer attached to the exhaust flap, when this happens the exhaust flap is free to move around, and what tends to happen is that the exhaust flap butterfly is not 100% opened with the exhaust gasses exiting the left hand tail pipe, this creates a small obstruction and the noise is created as a result..



    If thats whats happened then im sure its ok, I ran my car like this all the time I had the standard exhaust on my car..

    If its not that then it could be something further up the exhaust, I doubt it though as it would be extremely loud inside the car and the noise would be all of the time, not just on boost as your describing

    Jonny
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  21. #20
    JamS3's Avatar
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    The air pipe to the flappy exhaust thing can be seen underneath the rear bumper in the upper left hand corner, check that is attached to the flap also mate.
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  22. #21
    L60N
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    Cheers guys,

    Just back home from training. I had a peek before i set off, and before I saw jonny's posts above but managed to find the solenoid (Doh).

    It seems to be operating ok, I.e closed, then u can open it by pushing up.

    I havnt tried the pipe yet though Jams3 so thanks for that, i'll have a looky.

    Just for information, im starting the think the solenoid is sticking because the noise stops after the car has been allowed to cool.

    I.e.

    @ 1pm Firstly it was ok, then after a spirited drive the problem arose.
    @ 4pm Firstly it was ok, then after taking it for another spirited run it re appeared.
    @ 7pm tonight, it was ok, didnt drive it harsh either way and its still seems fine..

    So im guessing if i go flooring it again i can make the issue re appear?!?

    P.S. did the sound clip open ok for you guys? It was a bit on/ff when i tried it earlier..

  23. #22
    mitch78's Avatar
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    Last edited by mitch78; 19th March 2009 at 22:19.
    Ex 8L S3 driver

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  24. #23
    Iggu's Avatar
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    You sure this is in no way related to your GIAC map. Seems a big coincidence that it all starts a few days after your remap. Does the GIAC software not change the exhaust note in some way once you go over a certain rpm or something - i.e. is the noise not an intentional accompaniment to a spirited drive ?
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  25. #24
    L60N
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    Quote Originally Posted by Iggu View Post
    You sure this is in no way related to your GIAC map. Seems a big coincidence that it all starts a few days after your remap. Does the GIAC software not change the exhaust note in some way once you go over a certain rpm or something - i.e. is the noise not an intentional accompaniment to a spirited drive ?
    It wasnt there before yesterday.

    THere was a definate change to the exhaust - turbo noise immediately after the remap which i expected, but this noise seems like something has definately changed with the hardware.

  26. #25
    jonnyc's Avatar
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    Did you check the exhaust flap?

    Id say its time for a Milltek TBE
    MK5 ED30.. Fastest MK5 / 2.0T FSI in the UK - Fastest DSG MK5 in the world!

    12.601 @ 115.85 MPH

  27. #26
    L60N
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    Flappy seems to be working ok, i.e. its moving freely with a little pressure. THe exhaust sounds fine from cold, and as long as i dont take it up into the redline it stays ok.

    As soon as i open it up for a period of time, the noise comes back after a while..

    I'll give it a blast today, till the noise comes back, then recheck the flap (with some heat resistant gloves

  28. #27
    jonnyc's Avatar
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    Sounds like a plan mate!

    Sounds like its sticking with heat like you say, as you can see from my pics the OEM exhaust gets pretty ****ty after a few miles..

    Jonny
    MK5 ED30.. Fastest MK5 / 2.0T FSI in the UK - Fastest DSG MK5 in the world!

    12.601 @ 115.85 MPH

  29. #28
    DeckedS3's Avatar
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    I still think you should have a look at the cat.... I blew a hole through mine and when I booted it the lumps of mesh moved about inside until it had all broken up and blown out the back. Was the road wet when it first started? often they crack and split up if the exhaust is hot and you go through a big puddle that cools the outside too quick. I presume you don't have an engine check light on?

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  30. #29
    jonnyc's Avatar
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    If it was the cat then the sound would be constant.. And pretty loud seen as how the exhaust would be exiting 2 feet from the turbo
    MK5 ED30.. Fastest MK5 / 2.0T FSI in the UK - Fastest DSG MK5 in the world!

    12.601 @ 115.85 MPH

  31. #30
    L60N
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    It was ****ty weather yesterday. Theres no lights on the dash. I hope its not the CAT!!!

    Did u guys manage to listen to the clip. What did you think?

  32. #31
    jonnyc's Avatar
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    Hard to say from listening to the clip, is it very loud, or just the standard exhaust noise +??

    Could possibly be a broken baffle in the rear silencer..

    If so it could be warrenty or you can buy my standard exhaust..

    Jonny
    MK5 ED30.. Fastest MK5 / 2.0T FSI in the UK - Fastest DSG MK5 in the world!

    12.601 @ 115.85 MPH

  33. #32
    L60N
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    I'd say very loud!! exhaust noise++++++

  34. #33
    jonnyc's Avatar
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    Hmmm.. Can you identify where the noise is coming from? If its the tail pipes then its more likely that its the baffles in the exhaust..

    Can you hear any rattling from the silencer boxes?
    MK5 ED30.. Fastest MK5 / 2.0T FSI in the UK - Fastest DSG MK5 in the world!

    12.601 @ 115.85 MPH

  35. #34
    L60N
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    No rattling, but with the windows up. It sounds very loud coming from the boot area.

    Its wierd how it only does it after a thraping. Either the solenoid is sticking, or its a loose baffle being agitated during a heavy run.

    I'll go on a blast tonight, get it going again, then check the solenoid, if all that is still ok, i'll drop it in to audi to have a look at..

  36. #35
    DaveS3Turbo's Avatar
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    Can you pin the solenoid with a clip of some sort to keep the noise?

    Are there any down sides to opening the flap permanent?

    David
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  37. #36
    L60N
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    Prior to setting off from work, checked under the exhaust and gave the solendoid arm a quick couple of presses for luck, slid in and out fine so headed out to the empty country roads.

    A few minutes in and the howl reappeared

    So i pulled over to re investigate the exhaust. Seems the solenoid is opening up too much and getting stuck:



    I couldnt pull it back out because the darn thing was red hot!!

  38. #37
    L60N
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    Went back out to try and pull it down with a screwdriver. But after only 5 minutes cooling its dropped back down of its own accord. But whilst in use and warm its stuck in the air


  39. #38
    jamiekip
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    Sounds like a warrantly job to me.
    Out of interest, have you tried loading up the stock file and going out for a blast?
    Same problem????

  40. #39
    L60N
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    Quote Originally Posted by jamiekip View Post
    Sounds like a warrantly job to me.
    Out of interest, have you tried loading up the stock file and going out for a blast?
    Same problem????
    Nope,

    Im going to have a tinkle first, if its just a sticky valve, should be able to sort it myself rather than give it to Audi for a week!

  41. #40
    DaveS3Turbo's Avatar
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    Is it not a nice noise?

    Would this have any adverse effects If i wanted the exhaust louder?

    David
    2012 Porsche Cayman R Peridot Green MY12
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