Boost leak, really need new ideas now. leak graph inside.

JJ.Foulds

JJ.Foulds

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Car: 2.0 A3 TFSI quattro 05 plate. remapped.

The red line is the requested boost from the engine, and the green line is the actual boost.


imgurl

As you can see i have a leak, a leak of 1/3 of my total boost.
I have a front mount intercooler from eBay which i thought was causing the problems. Today i swapped all the pipe work back to standard, and had the same results, so it is not any of the piping from the metal turbo outlet right to the intake manifold as i have just redone all the pipework and it seems all tight and secure.

So on to other ideas, the recirc valve, this was new about 18 months ago, however on my k03 it is located at the turbo which the heat can damage the rubber. I have now done a dumpvalve relocation and now its at the front, i am ordering a GFB DV+ which replaces my rev D piston.

I have also ordered a PCV forge delete plate incase this is the issue.
I have also visually checked the rear PCV pipe and no rips and looks secure.

My worry is that these tiny issues may not be the problem of the large looking leak i have.
I just need some ideas from you guys on what to do or look for, my last resort is going for a boost leak test, which a remapping garage local to me does, but doesn't use smoke.

ALSO im a little worried about my boost pressure, it says 2500mbar on the picture for the top line, and most boost gauges only go to 2bar. Or am i missing something here?

Any idea are very grateful :)

Thankyou.
 
JJ.Foulds said:
Car: 2.0 A3 TFSI quattro 05 plate. remapped.

The red line is the requested boost from the engine, and the green line is the actual boost.


imgurl

As you can see i have a leak, a leak of 1/3 of my total boost.
I have a front mount intercooler from eBay which i thought was causing the problems. Today i swapped all the pipe work back to standard, and had the same results, so it is not any of the piping from the metal turbo outlet right to the intake manifold as i have just redone all the pipework and it seems all tight and secure.

So on to other ideas, the recirc valve, this was new about 18 months ago, however on my k03 it is located at the turbo which the heat can damage the rubber. I have now done a dumpvalve relocation and now its at the front, i am ordering a GFB DV+ which replaces my rev D piston.

I have also ordered a PCV forge delete plate incase this is the issue.
I have also visually checked the rear PCV pipe and no rips and looks secure.

My worry is that these tiny issues may not be the problem of the large looking leak i have.
I just need some ideas from you guys on what to do or look for, my last resort is going for a boost leak test, which a remapping garage local to me does, but doesn't use smoke.

ALSO im a little worried about my boost pressure, it says 2500mbar on the picture for the top line, and most boost gauges only go to 2bar. Or am i missing something here?

Any idea are very grateful :)

Thankyou.
Click to expand...
My mates can do smoke test if your near Sheffield?
 
Paul @ Unit 9 Remaps said:
were are you based we do boost leak testing via smoke / UV and are in the north east
Click to expand...
Im in Grimsby area which is east coast below Hull.

So both sheffield and yourself are quite far away.

What test can actually be done without smoke to find the leak? compressed air and an ear?
 
JJ.Foulds said:
Im in Grimsby area which is east coast below Hull.

So both sheffield and yourself are quite far away.

What test can actually be done without smoke to find the leak? compressed air and an ear?
Click to expand...
no not just compressed area, the only way DIY i would try to see if you lucky is maybe shaving foam but honestly get it done properly and you will find it in minutes instead of messing on which you most likely wont find it
 
fouryoghurts said:
<=Stage 1 should be <=~3bar as unmodified tract will get a hard time at higher values.
Mapping guys will be able to confirm this?
Click to expand...

was just doing some google research and i think its generally 1.2 bar remapped just a stage 1.
And most guages are up to 2 bar, not sure.
 
JJ.Foulds said:
was just doing some google research and i think its generally 1.2 bar remapped just a stage 1.
And most guages are up to 2 bar, not sure.
Click to expand...

Yes 2bar above atmospheric...hence why live data reads <=3bar.
I.e. Boost guage displays boost only (surprise surprise) upto 2 bar but the total pressure, including atmospheric, is upto 3bar. So the 1 bar offset is there if atmospheric is factored in - as per your original boost pressure sensor graph.
 
Last edited:
fouryoghurts said:
Yes 2bar above atmospheric...hence why live data reads <=3bar.
I.e. Boost guage displays boost only (surprise surprise) upto 2 bar but the total pressure, including atmospheric, is upto 3bar. So the 1 bar offset is there if atmospheric is factored in - as per your original boost pressure sensor graph.
Click to expand...


Ahh great, thanks for clearing that up, i understand now. so im actually boosting 1.5 bar above atmospheric.

Thanks for that.
 
so today i fitted the blanking plate, i still have a boost leak... lol. However the graph not only slightly increased but throttle response is better. didnt fix my problem tho.
 
audi upgrades
Rick @ Unicorn Motor Dev. said:
Boost here is absolute, gauge pressure is 1000mbar less, so you are requesting a peak of 1.5 bar. Very few Audi's will run 2 bar of boost.

I suspect your DV is leaking.

Rick
Click to expand...

Iv just purchased the GFB DV+, so if it is the dv thats that sorted.
But the original dv was less than 2 years old!

I will also have a visual inspection of the original intercooler tomorrow,
Any places this might damage that i can look for?
 
Rick @ Unicorn Motor Dev. said:
Boost here is absolute, gauge pressure is 1000mbar less, so you are requesting a peak of 1.5 bar. Very few Audi's will run 2 bar of boost.

I suspect your DV is leaking.

Rick
Click to expand...

Also i didnt think the Rev D valves leaked as there is nothing to rip? this still may be the cause of a 1/3 boost leak?

Thanks for replying also.
 
Ok so iv fitted the DV+, the boost gained about half a box worth from the picture perspective. however boost is a little more smooth.

I do still have a leak, is the original intercooler something to look at? plastic edges etc?
 
Just to reiterate since everyone saying it is getting ignored, needs a proper pressure test!!!
 
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Reactions: Paul @ Unit 9 Remaps
Sayam said:
Just to reiterate since everyone saying it is getting ignored, needs a proper pressure test!!!
Click to expand...

Everyones saying what? ha.

But yeah been in contact with a local pressure tester, will be going soon and i will post results.
Thanks everyone.
 
Quick question, Does the oil cap need taking off for pressure testing? to save the seals or something.

Thanks.
 
JJ.Foulds said:
Everyones saying what? ha.

But yeah been in contact with a local pressure tester, will be going soon and i will post results.
Thanks everyone.
Click to expand...

Saying you need pressure test to establish where the leak is
 
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