cracked UrQ em

[isham-research.freeserve.co.uk at pop.pol.net.uk]

> Well, it's worse than I had hoped, and now there's no chance of driving the
> car to the ALMS at Seca (I'll be there anyway :) ...  BOTH #2 exhaust studs
> have snapped off, and the manifold is visibly warped-once I got the turbo out
> I could see the # 2 gasket hanging halfway out of the port, and a gap of
> about 2mm between the head and manifold at the flange.  Then I noticed the
> large crack in the baffle at the outlet :(
> It was about that time that my buddy started whispering "Stage 2...Stage
> 2..."  Thanks so much for all the replies + help...I'm not sure yet if I'll
> source a new one or go with the 2 piece 200tq part... I'll keep ya posted.
> As long as I can have it at Sears Point in November for the QCUSA school I'll
> be happy :)  Thanks again!

The two-piece part requires a _LOT_ of metal-bashing to the downpipe
just behind the turbo flange - like about a 6mm deep 'egg'?  We've done
one, but the resulting cross-section of the pipe at that point - inches
from the turbo exit - just can't be right.

My current (and frequently voiced) opinion is that there is ABSOLUTELY
NOTHING wrong with the design of Audi's original exhaust manifold and
that it could easily last the life of the car.  The main culprit is
rust eating away the right engine mount heatshield and heat subsequently
wrecking the engine mount, causing the engine to sit on the subframe
and apply hammer shocks to the turbo/manifold assembly.  Despite all
(frequent) advice to the contrary, the heatshield _IS_ still available
from Audi - I bought four last week.  The part number is 857 199 386A
and the ETKA reference for your dealer is AQS/84/1/99/21-00 item 23.

Audi probably realised this fairly early on - look at how a 5000 mount
is protected from heat; a duct from the front of the car.

The engine mount is less easy - they differ a little by VIN.

Still very cheap insurance.  For those who don't know the state of
their engine mount - pass a strip of paper around the subframe under
the engine.  If you can't slide it round, the engine is on the
subframe.  Then check the heatshield ...

When we fit a heatshield these days, we usually add a little more rust
protection than even Audi provides.  It's unusual anyway in being a
fully painted engine bay component - rust protection has obviously
been recognised as important.

You cannot tell the state of an engine mount by exterior inspection with
it on the car.  I used to think you could - until last week.  I'll make
a .JPEG for anyone who's interested.  Also interestingly - the failed
part I discovered is a non-Audi (pattern) part.

--
 Phil Payne
 UK Audi quattro Owners Club
 Phone +44 7785 302803   Fax: +44 7785 309674