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relentless manifold problem with my audi s3

Discussion in 'A3/S3 Forum (8L Chassis)' started by Dan s3 audi, May 18, 2013.

  1. Dan s3 audi
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    Dan s3 audi Member

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    Well I brought myself a relentless version 2 (I believe) around nine months ago when I was re-building my blown up engine. I have done around six thousand miles since the re-build and I had recently started to notice I blowing noise coming from the engine bay when I started it from cold. this noise would then get much more quieter as the engine got hotter. So today I decided to have a look as I had a new turbo to downpipe gasket as this is what I believed was at fault. To my disbelief I found that my nearly new relentless manifold had a 3" split down it. I wont be driving the car anymore until this is fixed due to the fact I don't want anything brakeing and falling into my new CR hybrid. The car hasn't been running hot, two reasons for this. First being I had a professional custom map done by bill, second being I have never taking this car on any race days. It only ever has a quick blast here and there. So what could have caused this to break like it has done? I guess this will involve me taking the whole head back off the car again to change once I fined a new one? [​IMG] [​IMG] The crack is where it branched together to go onto the turbo
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  2. Lewis583
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    Lewis583 Member

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    Did you fit the turbo support bracket?
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  3. Dan s3 audi
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    Dan s3 audi Member

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    Yes it was all done to the books, no short cuts.
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  4. s3dave
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    s3dave TFSI Hybrid

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    [​IMG]

    Never seen them go there....hmmm
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  5. Dan s3 audi
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    Dan s3 audi Member

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    Have you any ideas to why this would have happened? will I have to take the head off to change?
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  6. cecilthesausage
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    cecilthesausage ...It's Never Finished...

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    I've bought 2 and sold them both on.... I think they are sh@te.... The money you save you end up spending putting them right.... Something I would prefer not to take a chance on.... Just my opinion...
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  7. badger5
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    badger5 RIP S3dave Site Sponsor

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    its what WILL happen on these, just a question of when not if - its a V2, and V3 was the one made of "better" material so they tell us.

    head off when we fit them as access is nightmare.
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  8. IrishDave
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    IrishDave Member

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    Yep that's my worry. I have a v2 mani, so far so good but for how long. I wish someone would develop and build a better tubular style manifold cough cough.
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  9. badger5
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    badger5 RIP S3dave Site Sponsor

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    something for you Dave :p
    [​IMG]
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  10. IrishDave
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    IrishDave Member

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    Thanks, but what I really need is a Badger5 mani:icon_thumright:
    #10
  11. s3mad_dude
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    s3mad_dude Noggies ruuuule!

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    I'll probably get shot for this but what's wrong with the standard one?
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  12. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Restrictive... <end/>...

    <tuffty/>
    #12
  13. daz-20vt
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    daz-20vt Active Member

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    Has there been a faliure on the v3 guys? Im looking to fit one soon but understandably dont want to do it twice. Seems a bit of negativity about the v3 but ive no idea why. Not on faceboom guess most info is on there? Daz
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  14. s3dave
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    s3dave TFSI Hybrid

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    V3 = Smaller runner diameters and some had mis-matched ports....Nicki seems to struggle with the power V the V2 on his maps..
    Last edited: May 21, 2013
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  15. daz-20vt
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    daz-20vt Active Member

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    Ahhh ok thanks for the heads up. What about if they are ported and how much difference are we talking. Its got to be better than standard hasnt it? Thanks again!!
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  16. s3dave
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    s3dave TFSI Hybrid

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    I have opened mine up a lot at the port openings, but time will tell on if or when its going to crack...:shrug:
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  17. daz-20vt
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    daz-20vt Active Member

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    Bloody things are a pita!! Guess porting it makes it thinner which means more likely to crack lol. Damned if you do damned if you dont. Thanks for the advice!!!
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  18. wild willy
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    wild willy Member

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    I run a V2 manifold and the crack timeclock is indeed ticking. The horizontal crack tells me that there is not enough give in the support bracket to accommodate the massive expansion that takes place. The collector is the weekest point and cracks in the direction of the opposing forces. I would have expected Mr prawns to have gone by now but i don't think any V2's have craked yet by people who run wmi. The stainless used in these manis is 304 stainless which does not like 900 plus degrees which some egts reach. Mine peaks at around 850 which although not much different may make the difference. Watch this space.

    Do you run wmi with your setup.
    #18
  19. IH786
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    IH786 Member

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    Same thing happened with my v2:

    [​IMG]

    Support bracket came loose - it MUST be fitted (properly) with these manis.

    I have got another v2 (i'm mad i know) which has been welded up by Dave - hope it last a bit longer!
    #19
  20. wild willy
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    wild willy Member

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    That's from a horror movie. Wmi active at the time? Any idea of what your peak egt's were. I'm more thinking the mani pulled the bracket loose because it couldn't adequately facillitate the expansion, rather than a loose bracket providing insufficient support. Not certain though.
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  21. badger5
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    badger5 RIP S3dave Site Sponsor

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    failure is inevitable houston ;)
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  22. wild willy
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    wild willy Member

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    Argh Bill, noooo maybe my manifold is different.... special....lucky.....:uhm:.
    Second thoughts can you put a spare manifold on standby for me please.:crying:
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  23. IH786
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    IH786 Member

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    Mine was not running WMI during the last few months - AEM kit was siphoning overnight.

    But then I was not driving the car flat out as my actuator was leaking and car was overboosting so was babying it as much as possible..

    Also when I put my car back together these past few weekends I noticed the exhaust was not sitting right, the mid section was too far back so when you bolt the decat in it was putting a lot of strain on the downpipe, which pulls on the mani.....

    So it can be said a combination of factors lead to my failure!

    But all resolved now. Plus had my second mani welded up even more than the last (to replicate the tabs present on the V3) so maybe this time I might get more than 4 months out of it before it cracks!
    #23
  24. IrishDave
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    IrishDave Member

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    Me too, hopefully before I get the engine put back together and back in the car;)
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  25. Chlippo
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    Chlippo Member

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    I am hearing sounds from my exhaust system and due to all those manifolds getting faulty I am directly suspecting its the exhaust manifold.
    Now before taking it off for inspection, and as we all know its a pita to fit, I am wondering if there is anyway to make sure that the problem is from the exhaust manifold and not something else. Any pointers or signs?
    Also my I managed to get 175 g/s max from my maf, I am doubting if this can be related. I tried different maps and in all couldnt get past that figure. I also tried another maf with same result. I run standard airbox with K&N panel filter.
    #25
  26. Searider
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    Searider Member

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    Are these XS Power manifolds in various guises?
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  27. s3dave
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    s3dave TFSI Hybrid

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    Try the mani to turbo gasket first..
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