Community Help

[fly300kts]

Hey Guys,

I need your help here: Got some pretty heavy maintenance coming up, 140K, and I am preparing all my stuff

2nd timing belt with all the bell and whistles
Carbon cleaning and I will do a DIY
Injectors cleaning and DIY as well
Shane's valve cover with DIY

Can someone map me the position of the intake manifold holes and as well as the port size



I would greatly appreciate

Phil

[CorneliusRox]

I am not sure what you mean? like the runner area?

Or all the bolts that you need to remove? I think those are all t27's except for two 10mm nuts (I think those are the right sizes).
Then there is one rod that goes down and connects to the block (support rod) and that is a triple square.

[fly300kts]

Sorry for not being clear
I am looking for the distance between each bolt, horizontally and vertically
I am looking for the length and width of the port



Phil

[CorneliusRox]

I see. I dont think I can help you there. I doubt the calipers will fit there. I would post this in the thread where everyone is group buying the S3 injectors and someone can measure when they have it off.

[mec]

Just had mine off yesterday. darn.

Give EPY a PM, I sent him a spare manifold a while ago.

[ericpaulyoung]

Ya I got a spare one from Martin for doing melt repair :) I can measure it tonight!

[fly300kts]

Ya I got a spare one from Martin for doing melt repair :) I can measure it tonight!

Thank you for the help Guys
Eric, looking forward to the data. If you caliper has milimeter capability, that will be even better

Phil

[ericpaulyoung]

Nope, only measures in ft-s/fortnight :)

Ah just kidding, I got a really nice mitutoyo caliper. Love the thing, had it since an engineering internship 15 years ago.
Eric

[fly300kts]

Nope, only measures in ft-s/fortnight :)

Ah just kidding, I got a really nice mitutoyo caliper. Love the thing, had it since an engineering internship 15 years ago.
Eric

Perfect !!

Phil

[fly300kts]

Eric,

You have PM

phil

[mr shickadance]

i can;t help you, but i am curious....why do you need the measurements? you always have cool shit a brewing

[fly300kts]

i can;t help you, but i am curious....why do you need the measurements? you always have cool shit a brewing

Surprise but you will know soon once I post the upcoming DIY's

Phil

[SykoraA4]

...are you 3-D printing a manifold?

[Hugh@EuropaParts]

...are you 3-D printing a manifold?

He's onto us Phil!

[Charles.waite]

Maybe a spacer? Or a billet flange for a custom mani?

[fly300kts]

...are you 3-D printing a manifold?

No, no intend to modify that
Much simple

phil

[fly300kts]

Maybe a spacer? Or a billet flange for a custom mani?

Nope
I am just being anal and want to make a tool

Phil

[ericpaulyoung]

For some reason I scanned that fast and read you want to make an anal tool.

Got your number, will call you tonight so you can walk through any specifics of the measurements you need.

[fly300kts]

And I just invested in the tool kit to remove the injectors and replace the Teflon rings.
Once done, I might just rent the kit



Phil

[ericpaulyoung]

And I just invested in the tool kit to remove the injectors and replace the Teflon rings.
Once done, I might just rent the kit

Phil

wow, I always just wiggle them out, cut off the old teflon ring with a razor, use a tapered punch to stretch and put the new ring on, and (this is the important part) wrap tightly with paper then tape to get the teflon compressed again, then re-install with a rubber mallet.

Geeze I feel like an Oakie saying that. :/

[CorneliusRox]

wow, I always just wiggle them out, cut off the old teflon ring with a razor, use a tapered punch to stretch and put the new ring on, and (this is the important part) wrap tightly with paper then tape to get the teflon compressed again, then re-install with a rubber mallet.

Geeze I feel like an Oakie saying that. :/

Nice! Can you take a couple pics and explain that better?

I just wiggle mine out by hand, clean the tips with a rag hit with brake clean, then reinstall. The teflon hasnt been an issue on mine.

One came out with the manifold!

All out

Before (90k)

After


No leaks or anything after reinstall. Or before for that matter.

[ericpaulyoung]

Audi used to require (or recommend) that you replaced the teflon every time. Now that is changed to "change if needed". Bman was the one that pointed this out, and he can probably cite the change. I have only changed my teflon on 3 sets. One of those sets I didn't wrap and compress the seals and they ended up getting destroyed. Basically it looks like the teflon ring slipped up when being installed because it was too loose, and it got cut on the edge of the slot.

[CorneliusRox]

nice fancy metal clips! My plastic ones broke so I run without. They stay in and dont leak just from the pressure of the manifold/fuel rail.

[B72011]

Wo hoo! New DIY's coming! Get your popcorn and pull up a chair! Love to see this stuff.
Dreading the day of reckoning with carbon cleaning ---but I want to keep my car for the long haul---so--eventually.

[ericpaulyoung]

nice fancy metal clips! My plastic ones broke so I run without. They stay in and dont leak just from the pressure of the manifold/fuel rail.

Damn man, I think I got a couple extra if you need them.

[CorneliusRox]

Damn man, I think I got a couple extra if you need them.

Nah, I'm good. Thanks though!

Honestly, I did my carbon cleaning when it was extremely cold outside and my garage wasnt much better (had ice on my boots by the end of it). I kinda rigged up the manifold and started the car to see if it would leak. It didnt at all, so I buttoned it up, and about 1000 miles after, I checked again and she is good.

Not worth it to me to tear that off just to toss clips in at this point.
If for some reason I decide to keep the car and make it a little more like yours, then I will get some.

[fly300kts]

Stupid question:

Do you know if there is an OEM tool to release all the stupid plastic connectors? Injector connector for example

Phil

[ericpaulyoung]

Don't think there is :/

[Charles.waite]

VAG Tool ID10T. Aka the flat head screwdriver. Costs $209.99 from you'r local VAG tool specialist.

But seriously, someone should make a tool that opens those damn plug connectors. I mean I've got the technique down mostly, but still, if there was a tool to do it that guaranteed you wouldn't break them, I'd buy it in a heartbeat.

[CorneliusRox]

The plastic ones just break! If you spin the metal thing a little and pull, you can get lucky

[fly300kts]

Did I found it?

http://vw.snapon.com/specialtoolsdet...temid=21710006

Phil

[LoKisSpYdR]

For some reason I scanned that fast and read you want to make an anal tool.

Got your number, will call you tonight so you can walk through any specifics of the measurements you need.

For the ANAL TOOL???

Jk. Can't wait to see what Phil has in store for us this time...love your DIYs. Couldn't / wouldn't do this shit without them.

[CorneliusRox]

Did I found it?

http://vw.snapon.com/specialtoolsdet...temid=21710006

Phil

light switch connector? I dont think so.

[fly300kts]

Gear box connector
Google the Pn

Phil

[CorneliusRox]

Hmm. It is too bad that You didnt make this sooner. At about 8am I was on the SnapOn truck and our guy is great. Used to be a BMW tech so he like stuff like our cars and he is pretty young. Maybe 30 and has his own truck.

He's off next Tuesday too... lol

[mr shickadance]

VAG Tool ID10T. Aka the flat head screwdriver. Costs $209.99 from you'r local VAG tool specialist.

But seriously, someone should make a tool that opens those damn plug connectors. I mean I've got the technique down mostly, but still, if there was a tool to do it that guaranteed you wouldn't break them, I'd buy it in a heartbeat.

1) push in

2) push down

3) slide out


troubleshoot

1) can't push in
answer: pahpush it real good

2) can't push down
answer: try a flat head

3) can't pull out
answer: 1) hahaha 'pull-out' 2) problem lies in small vacumn created by the connection, use a flathead or pick to disrupt the seal, then pull out 3)omgisaidpulloutagain

[shiro1745]

Phil's onto building a tool for carbon cleaning is my guess

[fly300kts]

Phil's onto building a tool for carbon cleaning is my guess

Getting closer

Phil