Stainless Steel 032 121 065 D Coolant Pipe.

Hello Mac,

The deposite was possibly a precipitate akin to limescale?

I was hoping for it to be a pink colour but it wasn't. This doesn't rule anything out.

Aluminum and another metal can cause galvanic corrosion but this small build up is most likely to be a deposite of some sort.
The alloy housing with a clean and even surface helps prevent leaks. The coolant pipe o-rings work well with a light covering of silicone grease.

All coolant pipes in this position on the engine are the same design AFIAK. (reference required)

How close is the fit, between the coolant pipe and the engine housing?

Its a snug fit and the engine is very close to the pipe.
20241210_092009~2.jpg

🙂👍
 
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My impression from the graph is that the ECU is controlling the temperature throughout.
The increase in radiator outlet temperature, (which indicates that the thermostat is open), seems to correlate with the rise in duty cycle, (which indicates the ECU has acted to open the thermostat).
The actual engine temperature tracks the setpoint pretty well. The maximum difference between setpoint and actual is around 10C, with the average, by my estimate, around 5C.
I don't see any evidence of the mechanical thermostat opening.

I'm curious about the Radiator Outlet Setpoint data, (light blue plot). I can't see any correlation between that Setpoint and the Actual. I wonder what function it might have, (if any)?
Mac.

Note: I am considering moving the last few posts to a new thread. This thread is specifically about the stainless steel coolant pipe, which ACS Cooling are producing for us.
Does anyone object?
 
Note: I am considering moving the last few posts to a new thread. This thread is specifically about the stainless steel coolant pipe, which ACS Cooling are producing for us.
Does anyone object?


Mac, hi there, I think your comment above is a good idea.
As I will be involved with this new pipe, it would help me just to have a thread only about this, as I am not always in front of my laptopop, so could miss some relevant information if it gets hidden in an off topic thread.

Any idea when the new pipe can be delivered to me for trial ??

All the best.
Martin
 
Note: I am considering moving the last few posts to a new thread. This thread is specifically about the stainless steel coolant pipe, which ACS Cooling are producing for us.
Does anyone object?


Mac, hi there, I think your comment above is a good idea.
As I will be involved with this new pipe, it would help me just to have a thread only about this, as I am not always in front of my laptopop, so could miss some relevant information if it gets hidden in an off topic thread.

Any idea when the new pipe can be delivered to me for trial ??

All the best.
Martin
I'm waiting on ACS for an availability date. They are aware of our testing plan.
Mac.
 
If a driver ignores the EML, the cause of the EML is unknown.
If it were the ECU controlled thermostat, again, with the EML being ignored, that failure would be unknown, wouldn't it.
I don't share the theory that the coolant pipe just fails. I think it fails due to coolant flowing through it being significantly higher than it should be.
I accept we'll never know, of course.
Mac.
I think the plastic pipe fails because heat AND pressure IE constance expansion and contraction
 
I'm waiting on ACS for an availability date. They are aware of our testing plan.
Mac.
Good stuff !! Today, I finally got the engine & box out of my car, & it's sittling on my work table.
Have already separated eng from box & starting to remove things & document how I did it, so that re-assembly should be as easy as is possible.

Tried to loosen the front pulley bolt, but not sucessful ; will attack it in a day or so, with a mega impact gun, borrowed from a friend. If they had designed the cam belt cover as a splitable item, there would be no need to even atempt to undo the pulley nut ! It only has to be undone to remove the plastic cover lower half, to get the cambelt out !!!

Just amazed at howmany conections (water & electrics) need to be undone to get at things ...... it takes me 3 hours to remove my 1974 Alfa engine & g'box ........ so far I have spent about 10 hours to get this far on the A2 !!!!!!!

1733850735004.jpeg
 
Hello Mac,

The deposite was possibly a precipitate akin to limescale?

I was hoping for it to be a pink colour but it wasn't. This doesn't rule anything out.

Aluminum and another metal can cause galvanic corrosion but this small build up is most likely to be a deposite of some sort.
The alloy housing with a clean and even surface helps prevent leaks. The coolant pipe o-rings work well with a light covering of silicone grease.

All coolant pipes in this position on the engine are the same design AFIAK. (reference required)



Its a snug fit and the engine is very close to the pipe.
View attachment 132577

🙂👍

I use PTFE, read somewhere it is best for o-rings that get too hot.
 
Hi everyone. I've just received an update from ACS, it's self explanatory, and a bit humbling too.
Mac.

"Unfortunately, we find it challenging to provide an exact timeline for the completion of the part you require. This is due to several reasons:

Upon analyzing the quality of similar parts currently in our possession, we identified several inaccuracies that we are striving to correct. To address this, we are manufacturing new tooling and revising the technological process. This is a creative and intricate task that is difficult to plan with precision.
Being located in Ukraine, we are subject to various external factors, such as power supply interruptions, workforce reductions due to mobilization, and others. These factors further complicate our planning efforts.
Given these circumstances, we estimate that the part may be ready by approximately December 25, but we cannot provide a firm guarantee.

We appreciate your understanding of the situation. Please rest assured that we are doing everything possible to complete the part for you as quickly as we can without compromising its quality, which remains our top priority"
 
Is this a 'Death Pipe', or is it the thermostat housing too?

Does anyone know what happened to @Phil_B 's stainless death pipe?
 
Hi everyone. I've just received an update from ACS, it's self explanatory, and a bit humbling too.
Mac.

"Unfortunately, we find it challenging to provide an exact timeline for the completion of the part you require. This is due to several reasons:

Upon analyzing the quality of similar parts currently in our possession, we identified several inaccuracies that we are striving to correct. To address this, we are manufacturing new tooling and revising the technological process. This is a creative and intricate task that is difficult to plan with precision.
Being located in Ukraine, we are subject to various external factors, such as power supply interruptions, workforce reductions due to mobilization, and others. These factors further complicate our planning efforts.
Given these circumstances, we estimate that the part may be ready by approximately December 25, but we cannot provide a firm guarantee.

We appreciate your understanding of the situation. Please rest assured that we are doing everything possible to complete the part for you as quickly as we can without compromising its quality, which remains our top priority"
This timing still works for me, as long as delivery time is reasonably prompt afterwards. l have plenty of other work to be getting on with ; manifold removal, clean up inlet valves & refit everything. Then there’s a slight oil leak to investigate & hopefully fix.

My aim is to perform a pressurised leak test once the steel cooling pipe is installed … l don’t want to only find out it leaks when l have the engine fully refitted in the car.

Regards.
Martin
 
I've just received a message from ACS Cooling, (yes, an FSI Christmas present).
The first, pre-production, part is ready.
I'll sort out payment and shipping over the next few days meanwhile, here's some pictures.
Have yourselves an FSI'zy Christmas.
Mac.
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Hi Mac
As a retired Aircraft welder of over 50 years experience on Aluminium,Titanium and Stainless steel TIG welding. The welding is not bad, but I can see numerous arc strikes above machined fittings. This usually has cold cracking in the arc strikes.I would recommend pressure testing before fitting
 
Hi Mac
As a retired Aircraft welder of over 50 years experience on Aluminium,Titanium and Stainless steel TIG welding. The welding is not bad, but I can see numerous arc strikes above machined fittings. This usually has cold cracking in the arc strikes.I would recommend pressure testing before fitting
I'd assumed that ACS would have done a pressure test, but I'll check with them today, and post the answer.
Mac.
 
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