Intake manifold removal

[03slatt]

Hi, I've got an error saying variable intake manifold stuck closed and I want to take a look, does anyone have any instructions on how to remove the intake manifold.

Thanks in advance !

[IanH755]

I'm away from my Laptop with ELSAWIN installed on it (the Audi tech manual) so I've had to use the online version of it following the link below. Now, as "dodgy" as the link address below may seem, its actually a "safe" site to browse but obviously never buy anything on it (or pay to disable ads etc) -

https://www.kolhosniki.ru/elsaonline&ve ... sl--3#file

[03slatt]

Brilliant thanks !

I was surprised to read drain coolant as a first step! Can this be done without removing all the coolant hoses ?

[Jim Haseltine]

You don't have to drain much, just enough to bring the level below that of the inlet port heater on the back of the manifold.

[03slatt]

So I managed to remove the intake manifold at the weekend, wasn't too difficult and only broke a couple of brittle pipes !

I vacuum tested the lower intake manifold flaps and both sides moved the same. I expected to see one side "flutter" or close as I get an error when driving saying one side is stuck closed. Has anyone else had this error or is it a possibility it got stuck closed and has now freed up after I've played about with it. Any opinions welcome, I don't really want to put it back together and find out I'm back to square one !

Thanks
Tom

[ATinOf]

I used to get this error a lot with a heavy boot, I ended up removing the intake manifold and the intake manifold flap assemblies, stripping them down to clean the carbon sh!te off them and refitting them. I still the get the error but its now quite infrequent. I have a rook of images I could post of the job if you need assistance with a 'how to', the plastic lever that moves the flaps is 'fragile' you have to watch you dont snap them stripping the flaps out.

I guess you could clean them to a degree without stripping them down but not as well.

You could remove the flaps and have them 'coded out' if you wanted; its one of the mods they do for increasing the engine power.

[ATinOf]

What I find quite funny is when you do get the error your revs are limited, to 4500rpm (or at least mine is); you can achieve quite a lot with these cars even at 4500 limit

[03slatt]

I used to get this error a lot with a heavy boot, I ended up removing the intake manifold and the intake manifold flap assemblies, stripping them down to clean the carbon sh!te off them and refitting them. I still the get the error but its now quite infrequent. I have a rook of images I could post of the job if you need assistance with a 'how to', the plastic lever that moves the flaps is 'fragile' you have to watch you dont snap them stripping the flaps out.

I guess you could clean them to a degree without stripping them down but not as well.

You could remove the flaps and have them 'coded out' if you wanted; its one of the mods they do for increasing the engine power.

What did you use to clean the flaps? Some kind of carb cleaner? I don't get limited revs it's just like a flutter or almost like the feeling of traction control and the engine light flashes on and off for 10 seconds then clears.

[ATinOf]

A good degreaser and a scotch bite pad but not solvent based, they're some kind of hard poly carbonate, a bit like the old melamine material

[ATinOf]

If you don't get the limiter with the error your not pushing her hard enough