Urgent help needed! Trying to remove intake manifold but

4.2 V8 40v biturbo - 450 bhp
4.2 V8 40v biturbo - 480 bhp (plus)
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p3u
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Urgent help needed! Trying to remove intake manifold but

Post by p3u » Thu Apr 15, 2010 2:55 am

something is preventing it from coming out. all of the bolts are off and there are 2 metal pin going into the back of the manifold front the inlets under the mafs. What do I do next? Car is apart and I'm stuck.\

Help greatly appreciated!

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Shoppinit
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RE: Urgent help needed! Trying to remove intake manifold bu

Post by Shoppinit » Thu Apr 15, 2010 12:53 pm

Have you disconnected the rear air pipes from the manifold?

Have you removed all 20 bolts from the top?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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RE: Urgent help needed! Trying to remove intake manifold bu

Post by Shoppinit » Thu Apr 15, 2010 1:05 pm

There are some sleeves in the rear air pipes that could be stopping you lifting the manifold off. It's not enough to remove the 2 horizontal bolts. You'll need to push the air pipes back and away from the intake manifold.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

p3u
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RE: Urgent help needed! Trying to remove intake manifold bu

Post by p3u » Thu Apr 15, 2010 2:55 pm

Yes, I have done this, but the air pipes will not move back any more then a few mm. What could be holding thrum in place? The only thing i think it coukd be is the metal pipe going into the air pipes that is held on by one bolt. I have removed the bolt, but they wont come off. Any thoughts.

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Shoppinit
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RE: Urgent help needed! Trying to remove intake manifold bu

Post by Shoppinit » Thu Apr 15, 2010 3:10 pm

They're connected to the turbos at the bottom with some jubilee clips, and also the hex head bolt that goes throught he breather into the rear air pipes. Last time I looked I chickened out at undoing the jubilee clip because access is almost non-existant. I think if you remove the 6mm bolts (EDIT: this is the one bolt you were talking about. You definitely need to remove it) that hold the crankcase breather pipe to the rear air pipes. THen you're just working against the resistance of the hoses at the bottom of the air pipes.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

p3u
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RE: Urgent help needed! Trying to remove intake manifold bu

Post by p3u » Fri Apr 16, 2010 5:58 am

I got it out! Thank you very much again!

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Shoppinit
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RE: Urgent help needed! Trying to remove intake manifold bu

Post by Shoppinit » Fri Apr 16, 2010 9:56 am

Cool. What was causing it to stick?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

p3u
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Re: RE: Urgent help needed! Trying to remove intake manifol

Post by p3u » Fri Apr 16, 2010 5:17 pm

Shoppinit wrote:Cool. What was causing it to stick?
Old age....

It was stuck on so good we had to get creative to remove the pipes. Got some rope, wrapped it around, stood on the manifold and pulled! Barbaric, but we tried everything else, I never want to mess with them again! 4 hours spent removing those two pipes!!!

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Shoppinit
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Re: RE: Urgent help needed! Trying to remove intake manifol

Post by Shoppinit » Fri Apr 16, 2010 5:26 pm

p3u wrote:
Shoppinit wrote:Cool. What was causing it to stick?
Old age....
Yours or its? :D

What were you removing it for?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

p3u
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Re: RE: Urgent help needed! Trying to remove intake manifol

Post by p3u » Fri Apr 16, 2010 6:03 pm

Shoppinit wrote:
p3u wrote:
Shoppinit wrote:Cool. What was causing it to stick?
Old age....
Yours or its? :D

What were you removing it for?
Ha, I'd like to think I'm fit at my ripe old age of 26 :wink:

I had a vacuum leak, hissing like a snake! The two way breather under the manifold seperated. Crap part if you ask me, I've had the same thing go out on a VW and another Audi, they always pop apart...

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Shoppinit
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RE: Re: RE: Urgent help needed! Trying to remove intake man

Post by Shoppinit » Fri Apr 16, 2010 6:05 pm

Good to know. Did you check your afterrun coolant pump while you're in there?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

p3u
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Re: RE: Re: RE: Urgent help needed! Trying to remove intake

Post by p3u » Fri Apr 16, 2010 8:31 pm

Shoppinit wrote:Good to know. Did you check your afterrun coolant pump while you're in there?
Ha, yeah it is toast. Found my coolant leak! :)

The new part number is totally different for it, and I had one person tell me its been relocated from under the manifold to the right side of the engine. Know anything of this?

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Shoppinit
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RE: Re: RE: Re: RE: Urgent help needed! Trying to remove in

Post by Shoppinit » Sat Apr 17, 2010 9:28 pm

Bonus! 2 birds one stone and all that :)

I've never heard anything about the pump changing place. Where did you hear that?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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