RS4: -- PART 2 -- Intake Manifold Carbon Build-Up & Clean U

[SpeedETC]

I ran a couple of runs today at lunch using my Ross-Tech cable and VAG-COM data but forgot to turn on S mode and disable traction control.

Anyone know how accurate this is? I was running four sample points in Turbo mode. It looks like it had sampling problems as the revs went up. I'll try runs with just Group 120.

My thoughts is block 120 is good for tuning, but not an accurate reflection of true power output.

[VVG]

Well since the first thread is huge I decided to create a new one to track progress.

The car is finally back together and just performing an oil change at 1:45am!! I can't believe how many damn screws hold the under tray in place. I am going to dremel out a hole in the tray so that I can quickly make oil changes.

With silverRS4s permission I am posting up some pics of his great work. Very happy with the visual results.

Tomorrow I'll get to see the true performance of the car. My experience has always been with the build up since I bought the car used with 38,000 miles from Audi Nashville. A new DRC suspension and clean motor and I'm set.

FYI, I am changing oil to Pennzoil 5w-40 Euro blend from the oilstore.com. I plan on changing it every 3000 miles and hopefully this will help the oil break down that could also be happening. A catch can will also be a priority for me as well.

Ported and Polished Manifold:
One thing to notice in the pics are that the trumpets are actually inserted in vs cast. This was something new that silverRS4 had not seen before. My car is an early production number.








Clean Intake Valves









One of the vanes before being cleaned. The build up is quite a bit as can be seen by the pics.

Did you do your own manifold removal? Did you have any help? Did you need any special tools to access some of those hard to reach sensors? How did you drain the coolant? When you put everything together, did you need all new clamps? Did you use Audi OEM clamps or did you go with easier screw type clamps?

Thanks for the info. Trying to tackle this project myself, but there is so little space to work around this engine.

[silverRS4]

There's a drain plug for the coolant on the thermostat housing (bottom, driver side corner of radiator). You only need to drain enough so that the coolant tank can be removed (about 2-3 quarts). Most single-use clamps can be replaced with standard clamps. The only sensor connection that's tricky is the passenger sider intake runner flap sensor (one of the two under the front carbon-fiber cover). Get a piece of stiff wire, grind down one end so its flat like a screw driver and bend it in the necessary shape to un-clip the sensor. The Bentley CD instructions for the removal is 13 pages, so its hard to give all the tips in one post.

[Sales@RAI]

has anybody thought about running some direct port meth injection? That would constantly keep the valves clean

[mattlqx]

There have been a few people that stated it didn't help but didn't give much details on what their meth set-up really was. If that's the case, then I'll install a system shortly after valve cleaning.

[jalas]

Did you do your own manifold removal? Did you have any help? Did you need any special tools to access some of those hard to reach sensors? How did you drain the coolant? When you put everything together, did you need all new clamps? Did you use Audi OEM clamps or did you go with easier screw type clamps?

Thanks for the info. Trying to tackle this project myself, but there is so little space to work around this engine.

Answers to your questions:

1) I removed my own manifold.
2) Only for the installation. It helped to have someone guide the intake around high pressure fuel lines, while I took care of the plastic intake flap arms.
3) I did not drain 2 or 3 quarts of fluid. That is not necessary. I did lose about 1/4 of a quart when working with the reservoir. I moved the reservoir out of the way only and plugged the hose and the tank. That was enough.
4) I bought new clamps from my local auto parts store.
5) silverRS4 has a good little write-up on the tools needed.
6) Patience is needed!!!!!!