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Water pipe failure...Potential disaster, Averted

Discussion in 'A4/S4 forum(B5 Chassis)' started by therealnovaboy, Mar 10, 2010.

  1. therealnovaboy
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    therealnovaboy Missed A Gear

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    [Mar 10, 2010]
    After yesterdays escapades I thought Id write up what has happened to make s4 owners aware of this possible problem.

    When doing a routine oil change I noticed a steal pipe running from the oil cooler weep coolant. On further inspection it seems that the metal pipe has corroded through to a hole. Realising that the pipe would have to be taken out and replaced I proceeded to turn the pipe in every possible orientation to try and slide the pipe out from between the front engine mount and block. However this was not possible without removing the front end and taking off the front engine mount. I made the decision to cut the pipe in the middle, slide it out and then fabricate a new pipe. You can see from the pics below that the pipe was very close to complete failure in several places, which would have resulted in very warm oil and possible engine failure.


    [​IMG]

    pipe removed and cut in half
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    close up of corrosion
    [​IMG]

    pipe was cleaned up to find many small holes and thin pipe walls
    [​IMG]
    [​IMG]

    new pipe made up from copper pipe and yorkshire fittings
    [​IMG]

    fabricated pipe in new location under engine mount
    [​IMG]
    [​IMG]

    it would my advice to check this component during a timing belt service interval as change out at this time would be straight forward.
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  3. Matt82
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    Matt82 Active Member

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    [Mar 10, 2010]
    does your car have its engine under tray still?
    #2
  4. therealnovaboy
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    therealnovaboy Missed A Gear

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    [Mar 10, 2010]
    yes. but it had to be removed during oil changing and pipe replacement. i will keep it removed untill i am sure there are no more leaks.
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  5. Matt82
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    Matt82 Active Member

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    [Mar 10, 2010]
    thats really interesting then. id have thought maybe stone chip damage could have started the corrosion on that pipe. maybe something was spilt all down there in the past and started the corrosion.

    bullet successfully dodged
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  6. therealnovaboy
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    therealnovaboy Missed A Gear

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    [Mar 10, 2010]
    no the standard pipe is located further up out of the way. if only audi's leaked more oil then this would probably never of happened. l0l
    #5
  7. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Mar 10, 2010]
    I'm not sure about using copper pipe on an engine...

    Copper tends to work harden quite easily and would then fracture...
    #6
  8. phoenixv6quattro
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    phoenixv6quattro staylowmovefast

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    [Mar 10, 2010]
    I can vouch for that, fabricated some copper pipe for my old 21 turbo. Lasted under 3 months before pissing everywhere!
    #7
  9. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Mar 10, 2010]
    Ye, the pipes only about 20 or 30quid new from audi by the looks of it...
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  10. phoenixv6quattro
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    phoenixv6quattro staylowmovefast

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    [Mar 10, 2010]
    Nice write up though buddy. Its good when someone takes the time out to post pics etc to make other owners aware of the potential problem, and gives them the heads up on how to fix it! FAIR PLAY.
    #9
  11. therealnovaboy
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    therealnovaboy Missed A Gear

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    [Mar 10, 2010]
    yes twenty to thirty quid is cheap but it would take hours to remove the front end to get the replacement pipe in place. which was not a job i was looking forward to do to replace one pipe. the copper should be fine i made a bracket to hold the copper from moving and fracturing.
    #10
  12. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Mar 10, 2010]
    keep an eye on it...
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  13. phoenixv6quattro
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    phoenixv6quattro staylowmovefast

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    [Mar 10, 2010]
    A very alert and watchfull eye.......
    #12
  14. Geeman
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    Geeman Low Life

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    [Mar 11, 2010]
    I had to have this very pipe replaced on my A8 2.8 as it was losing water through the same part!
    #13
  15. heymynameismark
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    heymynameismark Cool beans.

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    [Mar 11, 2010]
    Good write up that! :) Well done. As said, keep an eye on it though!
    #14
  16. olds_cool
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    olds_cool New Member

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    [Mar 11, 2010]
    Would my 2.6 quattro have the same pipe as I'm loosing water and can't see where from ?
    #15

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