Mikki's S2 almost complete, need advice

[Jake]

Hello all. I'm a new member here and would like to thank Mikki for putting together this brilliant forum. Mikki and I have been good friends for some time now and as you all probably know he's returned to the US perminately. He's asked that I finish his project S2 and put her back on the road, which I am truely honored to do. I began looking her over this last weekend and managed to get the rear end completely together and even began installing the Samco hose kit he left. This is where I need a little help.

I think I've got it figured out but there is one 3 way hose I'm not positive about. The Samco hoses make sense, but there is one that goes from the MAF sensor, down to the turbo and it has a small T midway down I have a question about.

There was one short piece of factory hose in the box that I think mates up to it. It's about 3 inches long, one end is about 3in in dia and the other end is maybe around 2.5in. It also has a small nub (T) that sticks out the side which appears to mate up to the Samco hose described above. Am I correct in thinking these two hoses mate up?

I ask because it’s clear that the short factory hose used to have a hose clamp that went around the OUTSIDE of the nub. It’s weird because the Samco hose would have to go around the outside of this nub. In other words, the OD of the nub, which normally took a hose clamp, is now the sealing surface for the ID of the Samco hose. I hope this is making sense.

Anyway, the problem is that the short factory hose has indentations from the hose clamp that used to be on there which doesn't seem to make for a very good sealing surface for the Samco hose to seal around. Assuming this is the way it was meant to connect, I've ordered another factory short piece so the OD of that nub is smooth allowing for a good seal with the Samco ID.

I don't have internet access at home for some reason but I'll be at work here for the next 8 hours or so and I'll check S2forum before I leave. After that I'll only have access to my home email because I won't be back to work until next Monday. If anybody could offer some advice it would be much appreciated. If you'd like to email me with some tips please do. My home email is bmwe30m3lover "at" aol.com.

Thank you guys,
Jake

[BosnianS2]

From what i understand you are trying to mate samco hose over hose that looks like factory piece. If both of those pieces are soft (rubber) i serously doubt that they will go on top of each other. If the other factory hose has clamp marks on it, then it probably had metal or plastic tube going inside it. There is no way that you can put rubber hose on top of other rubber hose and tighten them down and think that they will stay together. Especialy if they are under boost. If that is the hose that goes between MAF and turbo than they shoul mate without any adapters. This hose should have T that alows for installation of Bypass valve and also breather tube that comes from other side of engine on the block. Also there should be very small t that allows for installation of N75 (boost pressure) valve. this is how it looks on 3B code engines.

[Jake]

Thanks BosnianS2. I felt the same way when I looked at it, but nothing else seemed to mate up "naturally". I must be missing something in the box of hoses Mikki gave me. I'm headed to the dealer tomorrow to pick up a few parts and I'll bring the hoses with me and see if we can figure it out with their parts program. I sure wish I was there when he took everything apart.

Cheers,
Jake

[porkkis]

Original 3B bypass hoses have a short plastic pipe. I guess it's ment to be used with samco too.

[Jake]

Hmm... if that's the case it must be a reducer of sorts to go from the bigger ID of the Samco hose to the smaller ID of the stock hose it connects to. Hopefully the dealer can help me out there. Thanks again guys. I'll be away from the computer until Monday. I'll letcha know how I made out. And dammit Mikki, would ya call me or something! Sheesh... (smile)

Jake

[Jake]

Phew... ok, I've got internet back up at the house. Let's try this again please. Thanks for your help so far, I figured out what I was doing wrong (above). Problem was I was simply trying to work too fast. I want to get Miki's car finished so I can put it up for sale for him but I just need to slow down a bit.

Anyway, so I've figured out where all the Samco hoses go that he provided. However, its obvious I'm missing some parts. I'm going to run out in a few and snap some pictures to help you visualize what I'm talking about, but I'll try to explain first.

#1 The hose that runs from the MAF sensor to the turbo inlet has several extra T junctions coming off it. I figured them all out but one. As it arcs down just past the intercooler outlet, it has a T junction coming off that *just* misses the intercooler. In other words, the end of that nub points at and nearly touches the intercooler outlet. I have nothing that mates up to this.

#2 The intercooler inlet hose (coming from the turbo outlet) also has an extra T junction and again, I have nothing that remotely mates up to it. I do have one short extra piece of hose (about 1in ID) but its home is not obvious. I suspect it has something to do with these extra T junctions, but there must be something that fits between it and these T junctions.

#3 The hoses I have which I believe are meant to connect the intercooler outlet to the metal intake tube on top of the engine just don't seem right. There is a metal tube with a small metal loop type fitting welded to it that I think is part of this section, but it just doesn't route very well. There is an odd shaped Samco reducer that mates up to the metal tube (which is the only thing that mates up to this metal tube), but it needs to be slipped on excessively far to get the other end of the tube near the intake tube. Then there is a short Samco union piece that appears to connect the metal piece to the intake tube. Overall, this section does not seem right at all.

I hope this all makes sense. I'll head out now and get some pictures. I've not yet canceled Monday's MOT hoping I can figure out what I need and order it today to get it here before the weekend.

Thank you for your time and patience. I'm the owner of another cult type car and I know that it can be a bit irritating reading about somebody trying to figure something out they know nothing about. My only defense is just that I've been given a box of parts and a half assembled car and I promised to put her together for Miki. So please be gentle.

Jake Larsen

[BRY]

Where are you ?
Can't you get a forum member to come round with their car and do a "side by side" to get things sorted out?

[martinjs]

Get some pics up and we'll go from there.

[Jake]

Where are you ?
Can't you get a forum member to come round with their car and do a "side by side" to get things sorted out?

I'd really like to do that if possible. I'm in East Anglia in the village of Red Lodge just off the A11 near RAF Mildenhall. Anybody close?

Pics coming in a few minutes....

Jake Larsen

[Jake]

Ok, finally got all the pics loaded up. This first one shows the hose which runs from the MAF sensor to the turbo inlet. You can just see the T junction sticking out at the intercooler outlet. This is problem #1.





Here is a close up of that T junction. I have nothing in the box that would connect here.






And here is problem #2. This hose runs from the turbo outlet to the intercooler inlet. It has one T junction that doesn't connect to anything. It is possible to install it in either direction but I don't know which way is correct. This of course changes the position of the T junction as well. This one shows the T junction facing up and outboard at about a 45 degree angle.








And here is the same hose flipped around the other way.








Finally problem #3. This is the hose/tube assembly that runs from the intercooler outlet to the metal intake tube which runs across the top of the engine. This shows the components in the order I *think* the may come together.







Here it is installed. You can't see it, but the lower peice of Samco hose is pushed onto the intercooler outlet about 2 inches. The overall fit is poor in my opinion so I wouldn't be surprised if this isn't how its supposed to go together.







This pic shows (poorly) the contact between the MAF/turbo hose and the intercooler/intake tube and hose assembly. Unless the MAF/turbo hose is made incorrectly, the hose I've connected to the intercooler outlet is wrong and should have a T junction of its own in order to connect to the T junction off the MAF/Turbo hose. But this doesn't make sense either so I don't know what to make of it.







So what do you guys think? I know I'm missing stuff but god knows what. I was at the dealer yesturday and they couldn't help me one bit. I was hoping to at least bring the inlet hoses up on the parts program and ask them for a copy but they couldn't find a correct diagram.

Anyway, so thanks again and I appreciate any help/advice you can give.

Jake Larsen

[4WheelDrifter]

It looks as if you're missing the Diverter Valve. This should connect to #1 and #2 in your desciption.
HTH

[Jas11n]

It looks as if you're missing the Diverter Valve. This should connect to #1 and #2 in your desciption.
HTH

Yep, agree with Stu, looks like you are missing the diverter valve.
The second connection on the Maf to turbo hose is for the connection to the breather off the cylinder head.
I'm sure a small length of pipe is needed to connect the diverter valve to the turbo to intercooler hose.

Pic below shows standard S2 diverter valve.



Jas

[Jake]

Ahh... ok. Thanks 4WheelDrifter. I did some more searching and came up with a post about this hose kit where Newsh posted some pictures showing a plastic 90 degree elbow where it connected to the MAF/turbo hose. There was also some speak of a clearance issue between this MAF/turbo section and the intercooler outlet. Correct me if I'm wrong, but some have actually shortened the Samco hose to make a little room for the elbow. Does this sound right? BTW, here is the pic Newsh posted.







As for the Diverter Valve, I'd go back to the dealer for it but I'd rather ask here first. Miki always talked about a good chap that he'd go to for all his parts here on S2forum. Spoke of him like a god. So would somebody please point me in the right direction to order this DV assembly? Looks like I'll need everything. From the valve itself to any elbows or other plastic connections and required hardware. Feel free to send me a PM. There is literally nothing else that came with the car. Oh if only Miki where here...

Any opinions on the hose/tube assembly coming from the IC outlet to the intake pipe?

Thanks guys, we're making progress.

Jake Larsen

P.S. We must have been typing at the same time Jas! That picture helps a LOT! So that's where the long fabric covered vacuum hose goes too. I was wondering about that. Does it mount in a bracket or something, or does it just hang there in the hose? Just wondering if I need to order some type of bracket too. Thanks again!

[Jas11n]

Does it mount in a bracket or something, or does it just hang there in the hose? Just wondering if I need to order some type of bracket too. Thanks again!

Diverter valve doesn't mount in any bracket Jake, once connected to hoses and clips are tightened it doesn't move anywhere.

Jas

[Jake]

Just got off the phone with Allen at VAG and it looks like I'm all set. He was very helpful and even faxed over a few diagrams to help identify everything I need. You guys are correct; it was indeed missing the diverter valve. We also spotted the 90 degree plastic elbow necessary to complete the assembly so that's on the way too.

We also talked a bit about the Samco section connecting the IC outlet to the metal inlet tube. He guesses I have it right but the ill fitting was simply down to Samco's poor factory copy.

The one thing we weren't able to figure out was what I needed for the small metal loop on the metal tube sandwiched between the two Samco pieces which run from the IC outlet to the metal intake tube running front to back on top of the engine (item 25, fig 145-50). He thought there was supposed to be a bracket of sorts from the cylinder head or something off the heat shields (Item 9 or 17, fig 145-50) that mated up to that metal loop on item 25 to help steady the piping. However, both heat shields are in place but there is nothing near that loop that I could bolt to. Anybody know of a bracket or something that I may be missing?

Anyway, I also picked up some new front discs. Miki provided new rear discs/pads and new front pads, but no new front discs. It seems logical that he would want them too so they're on there way with the diverter valve stuff.

I gave Audi a call and rescheduled the MOT for the 16th so hopefully I'll have everything sorted by then. I can't wait to see this old girl back on the road. It's been Miki's mistress for so long (although parked for a few years), its time she got her wheels wet again.

Thanks for all your help fellas. I appreciate the hospitality. I'll keep you informed of the progress.

Cheers,
Jake Larsen