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  1. #1
    Active Member Two Rings
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    Question Oil in the intercooler.. Bad Turbo?

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    Hey Guys,

    So a little background on my situation. I recently replaced the Head Gasket on my 08 2.0T with 148k miles about 2 weeks ago. I had coolant in my oil. I pulled the head replaced the Head gasket, the engine block was fine, no warp, New head bolts, replaced the valve cover with a new one, The old one had this gooey yellow substance, Cleaned out the oil filter housing. Put everything back and she ran good, No Codes and no more coolant in the oil.

    A few days later I park my car overnight and the next morning I see oil stains on my driveway. I look under the car and the belly pan was drench in oil. I pull the pan off and see that oil was leaking from the bottom turbo hose onto the left intercooler. I thought maybe its just the old residue so I drained it out on both sides of the intercoolers, cleaned off the mess and went about my business.

    This Monday I noticed it again and same thing is happening all over again, oil is dripping. I pulled off the hoses and bam! more oil in the intercooler about a 1/4 of a quart. I check the oil return line on the turbo everything seems good. I check the DV and its the newest version that i changed last year. So back again i put everything back, this time I made sure I tighten the clamps on the hoses to prevent any more leaks.

    Tuesday morning I'm driving to work and my oil level warning comes on (The yellow one, Not Red) . I pull over and top it off. Wednesday I checked for oil stains on the pavement and nothing. Today I'm driving to dinner and again Oil level warning comes back on, I top off again.

    So now I'm thinking that my turbo is busted. Could the seals inside the turbo gone to sh*t? And the oil is now collecting inside the intercooler instead of returning it back to the oil pan. Theres no white or black smoke coming out from the exhaust, so its not burning it.

    Has anyone else had this type of problem before? I'm trying to get some input from other members before I go and try to find another turbo.

    Any help would be greatly appreciated.

  2. #2
    Veteran Member Four Rings oVeRdOsE's Avatar
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    I have this issue . and a lot of people here too.

    It's probably coming from the turbo journal bearing( blow by).

    there's not much oil, every oil change I would say around 10-20 ml.

    And I noticed it on a very well maintained 85 000km A4 (53k miles ). So , its not ''normal'', but for me, its not something that I will take care of soon.

  3. #3
    Active Member Two Rings
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    I would say 10 to 20 ml is minimal compared to what comes out from mines.


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  4. #4
    Veteran Member Four Rings Theiceman's Avatar
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    check your valve cover.

    the under side is likely cracked and you are pulling oil into your intake under vacuum. I'm betting when you torqued it down after you put your head back you didn't notice it had separated or it broke away while reinstalling.
    Very common problem

    checking for this is a 15 minute job , lots of pics here of bad ones if you hunt around a bit.
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  5. #5
    Senior Member Three Rings
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    Quote Originally Posted by Theiceman View Post
    check your valve cover.

    the under side is likely cracked and you are pulling oil into your intake under vacuum. I'm betting when you torqued it down after you put your head back you didn't notice it had separated or it broke away while reinstalling.
    Very common problem

    checking for this is a 15 minute job , lots of pics here of bad ones if you hunt around a bit.
    OP said the valve cover was replaced and is new.

  6. #6
    Senior Member Three Rings
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    Ah, disregard my previous post. I see what you’re saying about a potential problem installing the new valve cover.

  7. #7
    Active Member Two Rings
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    I thought about that first. But the VC is brand new.

    My guess is that the when the oil and coolant got mixed together it damaged the turbo seals and bearings.

    I’m fairly new with turbos. I’ve only owned the car for 2 years. Can the turbo be re-constructed? Or I’m better off getting another turbo from elsewhere?



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  8. #8
    Active Member Four Rings EvolutionArmory's Avatar
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    With a new valve cover and PCV parts, it doesn’t look good for your turbo. Wouldn’t it be pretty easy to check by removing the lower intercooler hose and looking for an oily mess in the cold side with an inspection mirror or borescope?

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    Veteran Member Four Rings canadianA4B7's Avatar
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    Quote Originally Posted by Hovesko View Post
    I thought about that first. But the VC is brand new.

    My guess is that the when the oil and coolant got mixed together it damaged the turbo seals and bearings.

    I’m fairly new with turbos. I’ve only owned the car for 2 years. Can the turbo be re-constructed? Or I’m better off getting another turbo from elsewhere?

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    I rebuild them. If yours is just seals it’s likely rebuildable. But until it’s open you have no idea what’s going on inside.

  10. #10
    Veteran Member Three Rings
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    Quote Originally Posted by EvolutionArmory View Post
    With a new valve cover and PCV parts, it doesn’t look good for your turbo. Wouldn’t it be pretty easy to check by removing the lower intercooler hose and looking for an oily mess in the cold side with an inspection mirror or borescope?
    I don't think he replaced his PCV yet?

    Can it be a bad PCV? A bad PCV can cause excess pressure and oil will come out of any weak spot (VC gasket/bolts, oil filter housing gasket, etc.) maybe the turbo too?

  11. #11
    Active Member Two Rings
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    Quote Originally Posted by EvolutionArmory View Post
    With a new valve cover and PCV parts, it doesn’t look good for your turbo. Wouldn’t it be pretty easy to check by removing the lower intercooler hose and looking for an oily mess in the cold side with an inspection mirror or borescope?
    I will try and take a look on Monday when I get a chance. Been really busy this weekend. I remember sticking a rag inside the bottom of the turbo to clean it out and there was oil. But I will use a mirror this time to get a better look. Thanks for the advice.


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  12. #12
    Active Member Two Rings
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    Quote Originally Posted by AudiKilla View Post
    I don't think he replaced his PCV yet?

    Can it be a bad PCV? A bad PCV can cause excess pressure and oil will come out of any weak spot (VC gasket/bolts, oil filter housing gasket, etc.) maybe the turbo too?
    I have a block off plate from BSH. Never had any issues with it. I did however replaced the gasket. But the plate is fine.


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  13. #13
    Veteran Member Four Rings canadianA4B7's Avatar
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    I don’t think your correctly venting the crank case. Which is leading to excessive pressure inside. This is likely pushing oil past the seals in your turbo. You must pull all crank and head air from these motors via a vacuum source. Take it from someone who’s done this before. You can use that plate just make a T between the crank gasses and the VC gasses and put them to the turbo inlet pipe.

  14. #14
    Active Member Four Rings EvolutionArmory's Avatar
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    Quote Originally Posted by canadianA4B7 View Post
    I don’t think your correctly venting the crank case. Which is leading to excessive pressure inside. This is likely pushing oil past the seals in your turbo. You must pull all crank and head air from these motors via a vacuum source. Take it from someone who’s done this before. You can use that plate just make a T between the crank gasses and the VC gasses and put them to the turbo inlet pipe.
    I think the best way to really narrow this down is to return the PCV system back to stock. Just take the unknown variable right out of the diagnosis process.

    These PCV systems are picky enough without people messing with them 😀

    Do you agree?

  15. #15
    Veteran Member Three Rings
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    Yup I'd get new OEM PCV. Your turbo seals could be the weak spot and the excess pressure is making it leak oil.

  16. #16
    Veteran Member Four Rings rhfosu's Avatar
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    Going through this as well. Turbo is brand new, as is the VC and the PCVs. Starting to worry my new turbo is bad.
    "I don't understand Audi enthusiasts. They buy a car that looks like a bar of soap, then they spend money modifying it so it looks slightly less like a bar of soap."

  17. #17
    Veteran Member Four Rings Theiceman's Avatar
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    So is there a way to determine if turbo is causing oil consumption issue as compared to rings for example ?
    Id hate to pull an engine to do pistons snd rings to find out it was the turbo.


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  18. #18
    Veteran Member Four Rings Theiceman's Avatar
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    Quote Originally Posted by rhfosu View Post
    Going through this as well. Turbo is brand new, as is the VC and the PCVs. Starting to worry my new turbo is bad.
    Or rings ??


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  19. #19
    Veteran Member Four Rings canadianA4B7's Avatar
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    Quote Originally Posted by Theiceman View Post
    So is there a way to determine if turbo is causing oil consumption issue as compared to rings for example ?
    Id hate to pull an engine to do pistons snd rings to find out it was the turbo.


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    Best to do dry compression test then wet compression test. This will confirm rings or valves. If those check out you can assume turbo or oil loss through seals somewhere.

  20. #20
    Veteran Member Four Rings Theiceman's Avatar
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    Oil in the intercooler.. Bad Turbo?

    Quote Originally Posted by canadianA4B7 View Post
    Best to do dry compression test then wet compression test. This will confirm rings or valves. If those check out you can assume turbo or oil loss through seals somewhere.
    Didn’t do compression check but car pulls very strong and scoped for scorred bores. They look fine.
    Car burns a litre in 300km. ( b8.5)


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  21. #21
    Active Member Two Rings
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    Thank you guys for all the input and help.

    I know water and oil don’t mix together but seeing that I had water in my oil would that damage the oil seals in the turbo? I probably ran the car about 75 miles before I noticed the damage that the head gasket caused.

    I will give it a try and return back to stock. I’m gonna order the PCV and the hose ASAP.

    In the mean time I will try to source a used turbo in case the PCV is not the issue.


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  22. #22
    Established Member Two Rings
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    Quote Originally Posted by Theiceman View Post
    Didn’t do compression check but car pulls very strong and scoped for scorred bores. They look fine.
    Car burns a litre in 300km. ( b8.5)


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    Yeah do a compression test. It only takes 5 minutes. I usually pull the fuel pump fuse and hammer the throttle to the floor and turn the car over 5 revolutions. Not sure if that's correct but hey it worked for me

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  23. #23
    Veteran Member Four Rings
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    Quote Originally Posted by Trickassfoo View Post
    Yeah do a compression test. It only takes 5 minutes. I usually pull the fuel pump fuse and hammer the throttle to the floor and turn the car over 5 revolutions. Not sure if that's correct but hey it worked for me
    Yes, a compression check is easy to do but don't read too much into it. It's my understanding that the ring problem on some A4s concerned the oil control rings in which case a compression check, wet or dry, will not tell you much. I'm not sure any 08 A4s had the ring problem though so some one check me on this. If you are going through as much oil as you indicate earlier in this thread, it's very unlikely the valves are involved (no pun intended). Also, a valve problem usually gives you a big burst of smoke on cold startup after resting for a while. You used new TTY head bolts when you replaced your head gasket, right?

  24. #24
    Active Member Two Rings
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    So I went ahead and swapped out the Block off plate back to the OEM PCV.

    And now I’m getting a misfire on cylinder 3. The coil packs are pretty new. Less than 10k miles on them. I changed the spark plug on the cylinder and am still getting a misfire.


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    Active Member Four Rings EvolutionArmory's Avatar
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    Quote Originally Posted by Hovesko View Post
    So I went ahead and swapped out the Block off plate back to the OEM PCV.

    And now I’m getting a misfire on cylinder 3. The coil packs are pretty new. Less than 10k miles on them. I changed the spark plug on the cylinder and am still getting a misfire.


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    Swap coil 3 to coil 2 and see if it follows. If it moves, it’s a coil. If it stays check your coil pack wire harness. If that is good, then you need to look into air or fuel and that means a compression test, leak down test or both or a possible injector or maybe something as simple as a carbon cleaning.

  26. #26
    Veteran Member Four Rings canadianA4B7's Avatar
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    Quote Originally Posted by Hovesko View Post
    Thank you guys for all the input and help.

    I know water and oil don’t mix together but seeing that I had water in my oil would that damage the oil seals in the turbo? I probably ran the car about 75 miles before I noticed the damage that the head gasket caused.

    I will give it a try and return back to stock. I’m gonna order the PCV and the hose ASAP.

    In the mean time I will try to source a used turbo in case the PCV is not the issue.


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    I can put together a turbo for you. I just need to do a rebuild for you. I think I have everything at home if interested.

  27. #27
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    Quote Originally Posted by EvolutionArmory View Post
    Swap coil 3 to coil 2 and see if it follows. If it moves, it’s a coil. If it stays check your coil pack wire harness. If that is good, then you need to look into air or fuel and that means a compression test, leak down test or both or a possible injector or maybe something as simple as a carbon cleaning.
    I will go ahead and do that. I’m not savvy on how to do a compression check. But I will swap the coils.

    I cleaned the head before I put it back on the block. Was able to remove a lot of carbon.


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  28. #28
    Active Member Four Rings EvolutionArmory's Avatar
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    You might have to pay someone for a compression test or buy the tester. It’s not hard to do yourself though. If compression on that cylinder is much lower than the others, you’ll know it’s a compression problem. If your compression is even within a few percent across the board and you said carbon build up probably isn’t an issue, that will probably mean you have a bad or clogged injector.

    If you had a problem like a fuel pump it would probably misfire on multiple cylinders. Since you only have a misfire on one clyinder, a coil, plug, compression, carbon or fuel injector is probably the cause. You just have to be methodical and rule them out one by one.
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  29. #29
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    Hi guys, I must revise the topic, since I've just rebuilt a 2.0T Audi, where literally everything is brand is new in the engine bay (I mean EVERYTHING), and it works 100% properly and perfectly, but unfortunately, I can confirm, the oil in the intercooler problem is there, constantly, by bad design... Even with oil catch can system. So I would decline all answers here, where someone think, you have engine component issues if you have any oil there.
    Last edited by effron; 04-23-2023 at 03:44 AM.

  30. #30
    Veteran Member Four Rings oVeRdOsE's Avatar
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    Quote Originally Posted by effron View Post
    Hi guys, I must revise the topic, since I've just rebuilt a 2.0T Audi, where literally everything is brand is new in the engine bay (I mean EVERYTHING), and it works 100% properly and perfectly, but unfortunately, I can confirm, the oil in the intercooler problem is there, constantly, by bad design... Even with oil catch can system. So I would decline all answers here, where someone think, you have engine component issues.
    even the turbo?

    Also does your catch can go a ''p trap'' in the lines. goes down, then up , then down.

    I found putting the catch can very low in the engine bay avoid hose to fill , and in my case, freeze during winter. I don't get a lot of oil in the CC.

    Still have some in the IC, but nothing major

  31. #31
    Veteran Member Four Rings Theiceman's Avatar
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    just saw some of my posts from earlier ... not related to recent posts but wanted to update some of my earlier comments.

    in my B8.5 it was the rings , but not the compression rings so a compression/leak down told you zero, but the oil scrapper rings were toast and the car runs fantastic now.
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  32. #32
    Veteran Member Four Rings Theiceman's Avatar
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    Quote Originally Posted by effron View Post
    Hi guys, I must revise the topic, since I've just rebuilt a 2.0T Audi, where literally everything is brand is new in the engine bay (I mean EVERYTHING), and it works 100% properly and perfectly, but unfortunately, I can confirm, the oil in the intercooler problem is there, constantly, by bad design... Even with oil catch can system. So I would decline all answers here, where someone think, you have engine component issues.
    first of all

    you do not crap all over a thread because your problem isn't fixed and you don't know how to fix it. ... a lot of the advice here is very solid and has been proven many times over.

    Secondly

    no one stated oil in your intercooler indicates your car is broke, in fact everything you read tells you its normal, the question is how much. i change my oil every 5k and every 5 years i get about a quarter cup out, i consider that normal. i dont check it run it check it again.
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  33. #33
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    Quote Originally Posted by Theiceman View Post
    first of all
    you do not crap all over a thread because your problem isn't fixed.
    First of all, I didn't say that at all. I said wrong answer were "where someone think, you have engine component issues".

    Quote Originally Posted by Theiceman View Post
    because your problem isn't fixed and you don't know how to fix it
    Secondly, I have nothing to fix, I have fingertip sized, crystal clean oil there next to a brand new longitudinal engine + fmic with zero miles in, just with pure idling. Maybe I'm a newbie here, but as a computer engineer, I was rebuilding my own defective engine without any helping hands by learning and reading service books, then cloned my ecu to a new one, then remapped with stage-1 mods, with my own bench tools, then I figured out my fuel issues by making ECG with my own oscilloscope, and changed lpfp to RS pump + r8 module, then reprogrammed the duty cycles with KFNTBKS, KLPSKRMX, KFFLAF, for fun. So, I believe, I may be able to figure out oil issues while I'm just an enthusiastic hobbyist, while you demote my knowledge.

    Quote Originally Posted by Theiceman View Post
    no one stated oil in your intercooler indicates your car is broke
    That is not entirely true. There are suggestions with "Bad turbo", "bad o-rings", "bad pcv", and "not normal" etc...

    Finally, I said, the oil is there, by design, it is normal to have some amount oil in the intake pipe and intercooler, since the oil vapors coming from a not vented PCV valve is connected with intake pipe.

    I really appreciate your information always, and respect your veteran knowledge, but you don't have to necessarily trash my opinion or ideas everywhere, just because I was asking for help in other topics with no veteran badge.
    Last edited by effron; 04-22-2023 at 06:20 PM.

  34. #34
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    Quote Originally Posted by effron View Post
    First of all, I didn't say that at all. I said wrong answer were "where someone think, you have engine component issues".



    Secondly, I have nothing to fix, I have fingertip sized, crystal clean oil there next to a brand new longitudinal engine + fmic with zero miles in, just with pure idling. Maybe I'm a newbie here, but as a computer engineer, I was rebuilding my own defective engine without any helping hands by learning and reading service books, then cloned my ecu to a new one, then remapped with stage-1 mods, with my own bench tools, then I figured out my fuel issues by making ECG with my own oscilloscope, and changed lpfp to RS pump + r8 module, then reprogrammed the duty cycles with KFNTBKS, KLPSKRMX, KFFLAF, for fun. So, I believe, I may be able to figure out oil issues while I'm just an enthusiastic hobbyist, while you demote my knowledge.



    That is not entirely true. There are suggestions with "Bad turbo", "bad o-rings", "bad pcv", and "not normal" etc...

    Finally, I said, the oil is there, by design, it is normal to have some amount oil in the intake pipe and intercooler, since the oil vapors coming from a not vented PCV valve is connected with intake pipe.

    I really appreciate your information always, and respect your veteran knowledge, but you don't have to necessarily trash my opinion or ideas everywhere, just because I was asking for help in other topics with no veteran badge.
    You said "decline all asnwers, where someone thinks you have engine issues"..
    While its is normal to get a little bit of oil in your boost system, over time. A substantial amount is not normal. And your def shouldny have any buildup, on a newly rebuilt engine, from just a little idling.
    Getting maybe an OZ or 2, after say 20k miles is "notmal". If someone is getting a lot, theres an issue..
    Besides the fact this thread is 5yrs old, lol.

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  35. #35
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    Quote Originally Posted by Jayz691 View Post
    You said "decline all asnwers, where someone thinks you have engine issues"..
    While its is normal to get a little bit of oil in your boost system, over time. A substantial amount is not normal. And your def shouldny have any buildup, on a newly rebuilt engine, from just a little idling.
    Getting maybe an OZ or 2, after say 20k miles is "notmal". If someone is getting a lot, theres an issue..
    Besides the fact this thread is 5yrs old, lol.

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    yes, you're right, 5 yrs old, but the b7 is much older. you can get oil fill there by not changing the oil in time, and not checking the IC for years. so it is just a bad stock design, that you can avoid with a little mod. I'm stating that there can be even a decent amount without any bad component, because of the bad stock design, and that is my opinion. that's all.
    Last edited by effron; 04-23-2023 at 04:06 AM.

  36. #36
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    Quote Originally Posted by oVeRdOsE View Post
    even the turbo?

    Also does your catch can go a ''p trap'' in the lines. goes down, then up , then down.

    I found putting the catch can very low in the engine bay avoid hose to fill , and in my case, freeze during winter. I don't get a lot of oil in the CC.

    Still have some in the IC, but nothing major
    that is a very good find, actually.

    But as you said, without putting the CC very low, the hose will fill, which is normal I think.

    I have thin layer of oil there with a new engine, but the previous owner had around 10 ml there without CC and proper oil change.
    Last edited by effron; 04-23-2023 at 03:54 AM.

  37. #37
    Active Member One Ring
    Join Date
    Mar 08 2023
    AZ Member #
    904165
    Location
    santa barbara

    Thought I'd share my experience with solving oil consumption on my 2007 a4 quatro 2.0:

    Engine was freshly rebuilt with new pistons, rings, head rebuilt, new Borgwarner k03 turbo charger as well. After the rebuild it was consuming 1 qt every 450 miles... I was finding about 2 cups of oil in the intercoolers. The mechanic that rebuilt the engine bought and installed a new Vaico valve cover as part of the engine rebuild. After trying everything else to solve the issue I purchased a new OE Audi valve cover. This solved my oil consumption! No more oil being consumed!

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