Water manifold leak, sealing?

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  • k.alle
    S2Forum Maniac
    • Feb 2008
    • 801
    • Country: Sweden

    #1

    Water manifold leak, sealing?

    I got a pressure test kit for the cooling system and found a leak at the water manifold tubing closest to the front.

    I have seal replacements (o-rings and funky shape seal) on order but I'm wondering if I should use some additional sealing compound when refitting?
    Is there a concensus on how to approach it or should I put my hopes on the new o-ring?

    See circled area in picture.
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    Audi S2 -1994 | 480 Hp 650 Nm | FlexFuel | MaxxECU | 3" Stainless | Porsche GT3 Front Brakes
    http://www.garaget.org/?car=52877
  • AndyP
    S2Forum Zealot
    • Feb 2004
    • 6049
    • Country: England

    #2
    I always put a bit of silicone sealant around the O ring, the yellow ones that come with the Victor Reinz gasket set are quite soft and easy to tear if you don't get them in straight.
    Check that your manifold is flat too.
    sigpic
    1991 Audi S2 3B - 2.5 Stroker engine
    1997 A6 2.5TDi quattro avant - C4
    1976 RD250E / 350LC cafe racer

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    • k.alle
      S2Forum Maniac
      • Feb 2008
      • 801
      • Country: Sweden

      #3
      Thanks for that AndyP

      Yes that's what I have on right now but without any additional sealant.
      They were Victor Reinz and the new ones are OEM, but surely its the same soft material.

      What kind of silicone do you use, high temp, specific for water etc?

      Good point on the flatness, I'll check that.
      Audi S2 -1994 | 480 Hp 650 Nm | FlexFuel | MaxxECU | 3" Stainless | Porsche GT3 Front Brakes
      http://www.garaget.org/?car=52877

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      • John.
        S2Forum Fiend
        • May 2012
        • 2615
        • Country: Scotland

        #4
        I did these on my S2 last week, the O-rings were yellow and I'm thinking they are original??...mileage is 75k I think. The O-rings that were fitted did appear super soft, I've just used some O-rings from a kit, rubber grease on them and it all fitted up back nice. AndyP Regards manifold being flat, assuming you mean condition around the triangular seal?


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        • AndyP
          S2Forum Zealot
          • Feb 2004
          • 6049
          • Country: England

          #5
          Just put a straight edge across all the faces as a check. I've seen them corrode too if the correct anti-freeze hasn't been used. I use the high temp silicone sealant.
          sigpic
          1991 Audi S2 3B - 2.5 Stroker engine
          1997 A6 2.5TDi quattro avant - C4
          1976 RD250E / 350LC cafe racer

          Comment

          • k.alle
            S2Forum Maniac
            • Feb 2008
            • 801
            • Country: Sweden

            #6
            Thanks for the input guys.
            Yes the o-rings is yellow.
            I'll stick with them since they work properly on the other runners but apply some silicone sealant.
            Audi S2 -1994 | 480 Hp 650 Nm | FlexFuel | MaxxECU | 3" Stainless | Porsche GT3 Front Brakes
            http://www.garaget.org/?car=52877

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            • Error404
              Super Moderator
              • Mar 2007
              • 19789
              • Country: United Kingdom

              #7
              I use Viton o-rings instead. The factory seals are soft and delicate as-said - and they swell in use so they are very much single-use. The o-ring spigot on the water rail is a stainless insert so they hold up well - not the triangular flange though, they corrode nicely.
              Like Andy said, check the flange is flat, use some silicone grease on the seals when you install. Pressure test.
              Panthero Coupé quattro 20vt
              Indigo ABY coupé
              Imola B6 S4 Avant

              Comment

              • k.alle
                S2Forum Maniac
                • Feb 2008
                • 801
                • Country: Sweden

                #8
                Hmm I'll keep Viton in mind if the yellow fails during install, use Viton all the time at work.
                Need to find out the sizes though.


                Originally posted by Error404
                Like Andy said, check the flange is flat, use some silicone grease on the seals when you install. Pressure test.

                You mean silicone grease as in lube, not a sealant product?
                Audi S2 -1994 | 480 Hp 650 Nm | FlexFuel | MaxxECU | 3" Stainless | Porsche GT3 Front Brakes
                http://www.garaget.org/?car=52877

                Comment

                • Error404
                  Super Moderator
                  • Mar 2007
                  • 19789
                  • Country: United Kingdom

                  #9
                  Yes grease to aid install, to help avoid damaging the seal
                  Panthero Coupé quattro 20vt
                  Indigo ABY coupé
                  Imola B6 S4 Avant

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                  • k.alle
                    S2Forum Maniac
                    • Feb 2008
                    • 801
                    • Country: Sweden

                    #10
                    I took the advices and fitted Viton o-rings and silicone grease.
                    Managed to shave off a bit from one during the install so had to do it twice, might be because of my 7A head with small chamfering?
                    O-ring size is 15x2.5 mm for reference.

                    The flange for the funky seal seemed straight.

                    Pressure tested to 1.5 bar and it didn't drop for at least ~45 min.
                    I also tested it with vacuum for 5-10 min and it held nicely, so all seems good now.

                    I was going to upload a picture or two but the forum seems to complain about file type, tried with both .jpg & .png .

                    [EDIT]
                    Where's my manners?
                    Thank you guys for the help!

                    Added pictures, manifold:
                    image_78273.jpg

                    The troublesome o-rings
                    20200521_131944.jpg
                    Last edited by k.alle; 1 June 2020, 08:39.
                    Audi S2 -1994 | 480 Hp 650 Nm | FlexFuel | MaxxECU | 3" Stainless | Porsche GT3 Front Brakes
                    http://www.garaget.org/?car=52877

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