better oring for turbo inlet

ive replaced 3C0129646 green oring 2 times on the turbo inlet and its still leaking is there any better oring i could use? any input would be great

I'm curious too.
I just replaced one since I had it take apart while chasing a coolant leak. Even after I put a new one in I still see some oil drips.
If there is a better option available, I would like to see it.

Max

Yes please!! *** there has to be a fix for this. My undercarraige is an oily disaster of a mess because of that stupid pipe dripping oil everywhere. Honestly, this ranks in my top 2 annoyances with this vehicle. The cam/DMF issues aren't even in my top 2.. T_T

yea i did a boost leak test and it leaks bad...

hodizz said:

yea i did a boost leak test and it leaks bad...

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You would think they'd make the turbo inlet airtight at the bare minimum, so ya know, only filtered air could make it in.

While I agree that is a common issue, that is pre-turbo, so it isn't a boost leak. The leak comes from normal crankcase vapors being drawn into the air inlet.

Usually it isn't enough to worry about, but in some cases it can seep enough to ruin the heater hose.

it is pre turbo but after maf... so wouldnt that affect things..or am i wrong..

That's the outlet isn't it? You don't get that ring on the intake? Not the centre hole but the lower one, the pipe comes off and heads to the IC? I reckon the metal of the actual pipe end has worn down to much so a new seal just wont do it any more.

oilhammer said:

While I agree that is a common issue, that is pre-turbo, so it isn't a boost leak. The leak comes from normal crankcase vapors being drawn into the air inlet.
Usually it isn't enough to worry about, but in some cases it can seep enough to ruin the heater hose.

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A boost leak test would just demonstrate that the turbo inlet coupling isn't airtight (at the minimum), which is part of the problem. Why that seal is so poor, the world may never know. Bottom line is that it's unacceptable. I can understand some sweating/weeping, but it just gets all over the place down there.

hodizz said:

it is pre turbo but after maf... so wouldnt that affect things..or am i wrong..

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The potential for unmetered air entering the turbo is so small as to be insignificant IMO with regards to running condition/performance; but that doesn't excuse the poor design.

Seatman said:

That's the outlet isn't it? You don't get that ring on the intake? Not the centre hole but the lower one, the pipe comes off and heads to the IC? I reckon the metal of the actual pipe end has worn down to much so a new seal just wont do it any more.

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Looky here for verification OP is correct
http://forums.tdiclub.com/showthread.php?t=296295

To bl00tdi
I had mine off recently( the plastic adapter on turbo for plastic flex hose from MAF)and I believe the way the part is made there is plenty of material in there to cut another groove for a second o-ring part #3C0129646. Would be an easy set up in a lathe to do so.

Ah is this one of those turbo damper things? The plastic thing that bolts on to the turbo itself? It has an o ring inside that sits against the turbo facing?

That is one place I wouldn't have expected a leak due to it not being under pressure.

I believe Robbie (runonbeer) has some slightly different sized o-rings on hand for just this problem.

Yes. Yes I do. I bought 100 viton o-rings with a slightly different total diameter and cross sectional diameter. I have been installing them regularly. It's a tight fit. You have to give it a forceful twist as you push it on but it feels very snug once it is wrapped all the way around.
I can't remember the size off the top of my head but ill have a look when I'm in the shop tomorrow.

The size I'm using is 4x45mm. I'll have to look in ETKA again to see what the stock size is.

thanks that be great

Stock size: 45,3X3,5mm

Is 45mm the ID of the o-ring?
yup, looks like 45mm ID.

runonbeer said:

The size I'm using is 4x45mm. I'll have to look in ETKA again to see what the stock size is.

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I purchased this size after reading your post but couldn't get the elbow onto the turbo, no matter how hard I tried. I lubed the o-ring and turbo itself, nothing. I'm no bodybuilder but not weak either. Any tips?


Edit: The ones I purchased were Viton. I wonder if nitrile would have a bit more give to it..

They are very hard to get on. You have to sort of twist and roll it up onto the inlet. I used to lube with grease but now I just drizzle some motor oil on the o-ring and inlet.
It hurts my hands. I'm not a big strong guy either.

Have had multiple cars with this o-ring installed come back through the shop for other things and all are nice and dry at the inlet. I think it is worthwhile. Probably there is a size somewhere in between that will be easier to install but equally effective. I really just grabbed the size out of thin air.

runonbeer said:

They are very hard to get on. You have to sort of twist and roll it up onto the inlet. I used to lube with grease but now I just drizzle some motor oil on the o-ring and inlet.
It hurts my hands. I'm not a big strong guy either.

Have had multiple cars with this o-ring installed come back through the shop for other things and all are nice and dry at the inlet. I think it is worthwhile. Probably there is a size somewhere in between that will be easier to install but equally effective. I really just grabbed the size out of thin air.

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That's what I like to hear! If they're still dry this seems like a permanent workaround, which I am all about. I guess I'll have to drink a red bull or my pre-workout drink before I attempt this again. Thanks for the input brother!

Just clear your mind. Know you can do it.

I find it helps to shine a light down into the inlet to give you an idea of what angle the inlet pipe is sitting at relative to the actual compressor housing, then just let your brain do the calculus.

Old thread: does anyone have a link to this o ring? I can’t find it.

Or has anything else has been proven to work? For the BRM that is.

BEWARE: I cracked my turbo inlet trying to force the bigger o ring over the turbo. I assume due to age.

I got it on and plastic welded it and epoxy’ed it so we’ll see.

Man I’m sorry to hear that.

Perhaps it is time for some repioneering here. As I said, I selected that o-ring size rather on whimsy and I agree it is really too tight a fit to be very useful. I am not sure which dimension to alter or by how much. I think it will just take some experimentation preferably by a single person to eliminate the subjectivity of installation difficulty. Then it would also have to be determined whether the newly chosen size is effective.

I am no longer exposed to these cars on a regular basis so I’m afraid I’m out as a candidate

Matt I think you’ll want to go ahead and replace that cracked inlet with a used piece. I just don’t see how an epoxy repair could be reliable here. This would also give you the opportunity to try an alternative o-ring size

Yeah I’m not sure. I feel like since it got over the lip of turbo the stress is now off.

It’s my sisters car so I’ll be watching it.

Optimally we would just need 45x3.75 which is right in the middle of stock and the original solution. But I’m yet to find anything between 3.5 and 4.