Intake manifold arm sheared

[arkavia]

Hi all, I have an emission engine light on. Just looked at the intake manifold drive arms and one is sheared. I've seen a replacement billet aluminium set available from the states. Is a rebuild fairly straight forward and is the most likely cause just a stuck flap? Would it just be wise to replace the entire manifold at a huge cost or are full rebuild kits available. I just read on here that some dude just paid nearly 4K! I mean WTF! Cheers in advance Guys. xx

[guffy]

No need to replace the whole manifold, although the stealer might say that! I’m not convinced the aluminium arms are needed either, as a plastic one will probably last until the next carbon clean if they do break. Equally you could do away with the flaps completely, quite a few people on here have done a ‘de-flap’.

If you're fairly handy with a set of spanners, then the manifold removal is reasonably straight forward, just time consuming, assuming you carry out a carbon clean while you have the manifold off (Which is a given really). I spent a weekend and a few evenings doing the job (I’m pernickety), it can be fiddly removing all the ancillary hoses, connections etc and cleaning the intakes (Probably an hour per intake with a range of fiddly tools, research this too as there are various methods). You’ll also need a very small ratchet spanner, search on here to find the link. You should also find a link for a step-by-step guide on how to remove the manifold too.

It’s an easy job to remove the flaps and the two shafts once the manifold is off so you can clean them and ensure they are rotating freely. Change the one-way valve under the manifold too, it’s only a tenner. It helps to take the plugs out when rotating the crank, if the plugs are near to the end of their life, might as well change them out. There’s no need to purchase a new manifold gasket, the old one should be fine.

Bit of a brain dump there, but food for thought.

[edge]

Id be more inclined to go for a De-Flap instead of a repair...

[adsgreen]

for the cost involved, I'd always say replace the gaskets.

if you have a broken arms then a deflap will require a remap as the sensors on the shaft won't register the movement.

[arkavia]

Ooh thanks I love it! 'One way valve Guffy?' Does it have a technical name? And can I buy the plastic arms separately from the rip off Stealer as I haven't seen any OEM replacements listed anywhere. X

[adsgreen]

No - dealer will sell intake manifold complete.

[caldy]

I purchased a s/h manifold to strip for a spare arm after I'd snapped one of mine. Thus I could dismantle the near side one if you were stuck. Can't remember if they're 'handed' or not.

[Rick_RS4]

there was a brokn manifold on ebay a while back , id email some breakers they might split the parts if the engines are being split,

also no need to change the gasket, they are re usable, they have some 2 or 3 small silicone channels that run round the gasket to form the seal, if they are sticking up its ok, if the gasket is flat id replace.

[adsgreen]

Sorry - I treat gaskets as disposable. I don't see the point with something so cheap not being renewed. Granted, it's not seeing any pressure and is only an air seal, but given how much they are clamped down and the heat they are subjected too no second hand gasket will be as good as new.