cracked manifold? AGU

[GolfGTI8v]

Hello all,

Before i took the engine out of my donor car Audi A3 AGU lump there was a loud blow from the exhaust around the turbo manifold area.  Unfortunately i didn't really investigate further as i was ripping the whole lot out i figured it would be obvious when i take it all apart.

Anyways engines now out on a stand ive inspected the manifold closely and it looks fine as does the downpipe and turbo housing. 

A few bolts holding the manifold on where not tight and took very little effort to undo.  Ive read these manifolds are prone to cracking is they anyway to test the manifold for hairline cracks that i cant see by eye? turbo is being replaced and i will be putting it all back together soon so i don't want to leave it to chance ? 

Regards

[Hulmie]

If there was a couple of loose bolts then it sounds likely the it would have been blowing from the manifold gasket. I would check the head to make sure the studs havent cross threaded in the head, therefore causing them to be loose.

Not sure if the manifold can be pressure tested.

[tech1889]

You can get your manifold presure tested mate or crack tested.. Check things above first though.

[GolfGTI8v]

Thanks for the info guys,

where about do crack testing?  im in Essex?     i may do away with it all together,  does anyone make/ recommend a higher flowing manifold that retains stock k03 mounting? using k03 hybrid.

i was looking to go k04 but by the time u source all the oil and water lines and brackets etc it cost a fortune for little gain over a k03 hybrid (unless sourced as a job lot which is proving difficult)?  i want the most cost effective way of obtaining 280ish budget is about £1500 for turbo/manifold.  was thinking maybe an ATP kit???

Regards

[Hulmie]

right, are you running a k03 hybrid or k03s hybrid? Not sure if there is a difference when hybrid

a stock cast manifold will do the job or have a look at THS as they do a cast high flow manifold with k03 fitment.

Also aiming for 280bhp i take it you have all supporting mods to acheive around this figure?

May also be worth looking at upgrading you fuel pump and injectors, bigger MAF housing

[tech1889]

They are both the same when hybrided.. K03 with k04 internals.. Only difference I can think of is intake pipe size..

Most engineering firms offer crack testing for a drink..

[GolfGTI8v]

Currently im running nothing as the engine is on a stand.   i was looking at ordering a k03s hybrid bought outright (not sure if anywhere will take my k03 on exchange)  the AGU lump came with a knacked k03 (lots of oil in intercooler) ive spent a small fortune on a quaife ATB diff, box rebuild with bolt kit, steel sump, vr6 clutch, lightened 16v flywheel, new OEM parts & sensors and other bits for my conversion. 

The outstanding list i require parts wise is

injectors  -- which to go for?
bigger MAF housing - which to go for? and should i just run an aftermarket induction kit?
intercooler & piping- ebay jobbie i think
FPR - 4 bar?
maybe fuel pump ??
turbo & possibly manifold
Thinking a Qpeng Mk3 2.5" downpipe and custom exhaust at my local place with sports cat.

im aiming for 280ish (to stay under what the stock internals can do) but im trying to figure out the most cost effective way of achieving it? theres tons of info out there but so much conflicting information my head ends up in a spin 

[Hulmie]

The outstanding list i require parts wise is

injectors  -- which to go for? Calibra turbo yellow or Saab Red
bigger MAF housing - which to go for? and should i just run an aftermarket induction kit? Maf housing is nothing to do with a induction kit. A mk3 vr6 MAF housing with the AGU MAF sensor fitted is what you need
intercooler & piping- ebay jobbie i think Spend the extra and get a THS Intercooler
FPR - 4 bar?
maybe fuel pump ?? Walbro 255 or Bosch 044 pump or Seat Leon Cupra R intank pump
turbo & possibly manifold Get your K03 repaired and hybrid for around £500, and get a cast manifold, avoid ebay cheap SS manifolds
Thinking a Qpeng Mk3 2.5" downpipe and custom exhaust at my local place with sports cat. You running this in a mk3 golf or mk4? 3 inch downpipe with sports cat, will help the turbo spool up quicker

[tech1889]

There is always oil in the intercooler from pcv system.. Someone on here got his turbo hybrided for £300 all in with a year warrantee.. As said above are good options.. Check the play in the shaft on the turbo if it's good get it hybrided and they will change oil seals etc during that process.. And a 4 bar fpr will be fine.. Get either forge or ths intercooler do it once do it properly

[Hulmie]

With the Saab Red or calibra yellow injectors there isnt much need to upgrade the fpr. These injectors run on tuned c20let engines on a 3bar fpr