fault code 00544 boost pressure upper limit exceeded

[kinaputt]

1. No noticeable air will not leak out at 1-2 bar even with a cold engine. It will take several minutes for the pressure to drop. If it was any other way you would have no compression in the engine.
2. 7A cams in stock position have no overlap.

If the head is alright it should be no problem, but he says the sound is from the WG, so the air comes from either the vacumlines or the exhaust. I said adjustable camgears, i had to turn my engine a bit, if it stopped while the valves was open to pressure test

[Monkeymagic]

Right i have just had it pressure tested again. I have now found 4 leaks which have been rectified.
I have emptied 2 bottles of fairy/water in a spray bottle and am convinced all pipes/joins are tight as the soap bubbles highlighted some very small leaks. However the spring vibration noise is still coming from the wastegate. I also noticed some bubbles coming from the port on the wg.? The noise will stop if i applied slight vacuum on the port.
I have sprayed soapy water all over injector seals etc etc and found no further leaks.
I can still hear air leaking somewhere around the intake pipe but am certain its not external..
I think im just going to drive it and see.

[prj]

Prj. The vag tool only has a gauge showing the pressure coming in so you can regulate it to 1.5 bar. You can feel the pressure in the tip and other pipes then drops off fairly quick. I can hear the slight hiss but soapy water has found 3 leaks but not this one yet.

Get a boost gauge or a tyre inflator and use that to pressurize the intake.
After putting some pressure in disconnect the air source or let go of the trigger and see how quickly the pressure drops to zero.
Touching hoses is NOT the way to go, as they are hard even with 0.3 bar in. Sounds to me like you have a massive leak somewhere that opens up at higher pressures.

Putting a constant 1.5 bar source behind it is not the way to go and you will not find the leaks.

All stock audi wastegates hiss when cold, this is normal, as otherwise they would seize solid when hot. Just blank off or pinch the pipe going to the wastegate.

[Monkeymagic]

Im just doing it the way the vag 1687 tool recommends. Running continuosly at 2 bar and spraying soapy water on. Tbe only leaks i found were from joints where the roose hoses were fitted. I replaced all jubilees with wider ones today that really tighten up well.
No leaks leaks were found. Well i just went out and can honestly say its never felt so responsive and smooth. Im still going to test the wastegate with a mityvac but think im on to something. Fingers crossed it was only a quick run in 2nd and 3rd but she was spooling up from 2.5 and flying from 4k like never before...

[Monkeymagic]

Two goods things have come from all this though. I tightened my alt belt to stop the annoying squeek and ive just noticed the accordian pipe is facing the wrong way. A job for another day!

[Error404]

Just in time for the weekend

[Monkeymagic]

It wants to behave itself for a while its testing my patience. I keep thinking my mk2 golf never gave me such aggro!!

[K Simmonds]

I keep thinking my mk2 golf never gave me such aggro!!

Me too, but was it as much fun?

[Monkeymagic]

Yes in many ways. But the whole reason the s2 won was the acceleration i guess.. next job change the accordian pipe. Anyone know how much difference it really makes?

[Monkeymagic]

We'll 40 miles in the coupe today and I can say it has never ever gone so well in my ownership. I have obviously had some small leaks for some time. It's smoother on idle and the throttle response in 3 rd is on and off and I seemed to have more torque when off boost. A very happy bunny til the next bit falls off... Haha.

[Monkeymagic]

Also I tested the wg with the mityvac and it held vacuum and slammed shut when released.