[s-cars] X-Plug saga continues

[Varon H. Fugman]

My X-Plug started leaking a few weeks ago.  For want of having the "correct"
Viton O-ring available, I tried a couple of generic rubber O-ring, which
only lasted a couple days each, and then a blue O-ring made for R134 air
conditioning.

The blue ring held up for 6+ weeks with no sign of deterioration.  However,
I wanted to put in the correct Viton O-ring, so I ordered the Power Steering
Pump Seal Kit 026 198 049BA which inlcudes several O-rings that appear to be
the right size.  However, when I installed the new Viton O-ring, it leaked
right away!

I quick put the blue 0-ring back in and it has held with the slightest trace
of seepage.  I'm guessing it didn't like to be disturbed.

The thing that is bothering me is when I tightened the X-Plug with the Viton
O-ring in place, it seemed to bottom out without any "cushyness" that I
would have expected from the O-ring compressing.

Is it possible that O-ring I selected just wasn't big enough (in cross
section)?  What do I do now?  Try another Viton O-ring from the kit?  Try
another blue O-ring?  They do look the same when I compare them.

Perhaps I need to clean the seat where the O-ring sits?

Ideas?

Varon
'95 S6 wouldn't be an Audi if it didn't leak somewhere!