servobrakes - blowed out the banjo bolt !

[EdgePerformance]

Anyone got an idea ? After a engine build on my Audi Coupè originally with 7a engine I have monted a AAN engine. On the first start up the powersteering fluid leaked out everywere around the pressaure valve screw on top og the powersteering pumpe. Then I got hold on a RS2 powersteering pump. Then I started it up. Every thing worked fine for a few minutes untill I started revving the engine. Then the banjo bolt for the brake servo on the pump blew out and dintet my custom intake. Something is terrible wrong. It builds up huge pressaure, and I dont know whats causing it.

Buy the way, the sensor on the servo brake pump with 2 poles. Is it only a pressaure gauge\switch or does it regulate the pressaure ? I took of the tube the goes onto the brake servo, and the oil poors freely out, but still it build up huge pressaure in the pump.

Im out of ideas and im about to go crazy ! Hope someone can help !

[Rusty]

Sounds like the circuit is blocked. I've cleaned mine using a pressure bleeder and a hose clamp between the tank and brake bomb.

[mcandmar]

I'm curious, what was the first PAS pump you used? And have you tried the original 7A pump?

[k.alle]

I've had the same issue, almost drove me completely nuts!

In the end I found out that I had mixed up the inlet with the outlet on the brake bomb, you could see the pressure hose starting to move a little bit then booom the banjo pretty much exploded

[s2driveruk]

ouch.....hope you werent close by when it let go, the operating pressure is high but to explode the bolt must be insane pressure buildup!

[EdgePerformance]

The inlet and outlet on the bomb has to be right. Every thing worked just fine before i took out the engine. I has been running with the AAN engine and S4 pumpe before i build the engine. I only took the hoses off from the pump, and from there through out the build the hoses has only been hanging down in the engine bay. Thats whats drives my insane. I havent moved a single hose ! Any other ideas ? The hole RS2 pump blew into 2 pieces and the banjo bolt could easely kill ! Watch out !

[Jamo]

Your assuming though, when diagnosing assumption is the mother of all f*ckups

Double check!

[EdgePerformance]

Just checked. The inlet and outlet on the bomb is correct.

[saltinot]

Both the banjo bolts on the ends of the hose have small screen filters embedded in them. Maybe these are clogged? Pull them off, soak them down with solvent, blow a little air though them in the reverse direction that the hydraulic fluid flows to clear the screen.

[EdgePerformance]

I haved done that. All banjo bolt filters are cleen and air blows through easely. I took of the bomb today as well and cleaned all pipes and hoses. Still the F***** pumps leek !

[saltinot]

Be aware that there are two different types of banjo bolts. One type is for use with crush washers and the other type is for use with o-rings. It depends on when your car was built. Earlier cars used the crush washer type.

Crush washer hose ends don't play well banjo bolts made to be used with O-rings AND vise versa. Also make sure that you have crush washers in place if you are using them and check to make sure that there is an o-ring on each side of the fitting on the ends of the hose.

[EdgePerformance]

The car was in perfekt condition when I took out the engine. The PSP is the same as used earlier and the O-ring banjo hose is the same as has allways been on the car. Does it ever happen the Brake-Bomb return valve on the top of it blocks\jammes so that the pressaure doesnt release and return to the fluid container ?

It builds up so much pressaure the last PSP craked into 2 pieces, and its so hard to turn that the engine wont even idle

[EdgePerformance]

Im so ****ed up tired with the servo brake crap ! The hole car is ready to be used, and the snow keeps falling down. Aka ideal quattro weather !

I would walk a hundred miles for any clues that might sort my problem.



At least my plane works

[S2central.net]

Wow - there's a forum 1st - someone posting a pic of their own lil plane... Cool !

There's two outlets of the PAS pump - one at very high pressure for the steering. One at lower pressure for brake servo. They are hard to cross up, but I'm wondering has the engine swap somehow allowed you to do so by mistake.

[k.alle]

You could try loosen the hose at the bomb and start the car, if it's spewing fluid out of the hose at least you know it's not the hose..
Then it has to be the bomb.

But sure, as Paul says also follow the hose so that you have not confused the steering/brake connections on the pump itself.