I carefully unbolted the vacuum plunger assembly and set it aside. Ready for the big clean of the manifold. The picture above is obviously with nothing attached to it.
In this picture you can see the bottom of the intake has been separated for manual cleaning. There are some hoses which are very difficult to remove so I left them on and made sure they were clear upon re-install.
NOTE: Be careful with the gasket in between these sections. You can’t get the part so you have to re-use it. Carefully pull it away from the mating surfaces and set it aside.
The main plenum was then worked on. I got the pressure washer on it with a degreasing solution and went to work with a brush.
The intake’s ports were really coked up and dirty. I used a Dremel tool to work it all off in each port. Then I used a scotch pad to clean the inner surfaces and especially the mating surfaces for the gasket.
Note: Pay special attention to the long channels where the shaft locate. Those areas will be lined with gum. A long thin brush and brake cleaner to is useful clean them properly. You want to ensure the cleaned shafts sit back in and move freely with no resistance.
Clean the intake shafts properly. The metal sections, and the nylon sections. Use a scotch pad on them to ensure they are free of any dirt.
Then reassemble the intake manifold lower section with its gasket. Reassemble the shafts into their respective ends, with their rubber seals.
Once the shafts are located, clean and dry. You can now re-install the flaps using thread locker on the screws. In this image you can see the cleaned flaps reinstalled.
Here you can see the 034 Billet Linkage Arms installed and the new Manifold Flap Position sensors installed.
With the manifold fully reassembled after cleaning there was zero play in the shafts. So an intake manifold can be refurbished if you want.
Whilst the intake was off the car I replaced all 4 Knock Sensors as well. The shiny cables in the middle of the V.
Then onto the carbon clean of the intake ports.
JamesBaby’s B7 RS4 Avant Daytona & Phantom
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