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    Thread: TSI Intake Manifold Removal DIY + Valve Cleaning

    1. Member EngTech1's Avatar
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      08-15-2011 09:42 PM #51
      My First Intake manifold Issues came at around 25,000 miles , but didn't get Fixed Until or
      Shell We say Figured Out - Till I went to a Different VW Dealer & Bitched !

      34,000 miles Fixed , Now It's got 54,000 Happening all over again !

      Tried the TSB on the Wiring Seems to have Helped but only - Lasted 3 weeks .
      How Long are Repairs Warrantied ?
      54,000 - plus a month of long distance Driving .
      Now 60,000 miles .
      ( Connection were - Firg'd Up - by the First Dealer ) , and the second - didn't Perform the TSB
      When the First Manifold was Done !

      Out of Pocket on the TSB - Wiring .


      Now comes the P2015 Code - WTF - this is a PITA !

      Is this the Part I need for the Fix , can this be done - without removing Manifold ?


      http://www.ecstuning.com/Volkswagen-...take/ES281203/
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


    2. Member 24vEngineer's Avatar
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      08-15-2011 11:14 PM #52
      Quote Originally Posted by EngTech1 View Post
      My First Intake manifold Issues came at around 25,000 miles , but didn't get Fixed Until or
      Shell We say Figured Out - Till I went to a Different VW Dealer & Bitched !

      34,000 miles Fixed , Now It's got 54,000 Happening all over again !

      Tried the TSB on the Wiring Seems to have Helped but only - Lasted 3 weeks .
      How Long are Repairs Warrantied ?
      54,000 - plus a month of long distance Driving .
      Now 60,000 miles .
      ( Connection were - Firg'd Up - by the First Dealer ) , and the second - didn't Perform the TSB
      When the First Manifold was Done !

      Out of Pocket on the TSB - Wiring .


      Now comes the P2015 Code - WTF - this is a PITA !

      Is this the Part I need for the Fix , can this be done - without removing Manifold ?


      http://www.ecstuning.com/Volkswagen-...take/ES281203/
      NO, your complete intake manifold is toast. The arm that actuates the flap is worn and is causing a small vacuum leak. Get a new intake manifold for around $275 from the stealership and then get this:

      http://blackforestindustries.com/blo...oil-separator/

      Enjoy taking off your intake manifold again!

    3. Member EngTech1's Avatar
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      08-15-2011 11:29 PM #53
      Quote Originally Posted by 24vEngineer View Post
      NO, your complete intake manifold is toast. The arm that actuates the flap is worn and is causing a small vacuum leak. Get a new intake manifold for around $275 from the stealership and then get this:

      http://blackforestindustries.com/blo...oil-separator/

      Enjoy taking off your intake manifold again!

      Wholly -Poop - This is really BS - there should be a - Giant Recall !

      Labor Rate going to be like $575 + Part - I Think I will Be doing the : Liquid Plastic - Maneuver

      My Miles are all Thruway - with the Cruise Control On - How the Hell could that
      Wear Out - Anything ?
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


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      08-16-2011 12:41 AM #54
      Quote Originally Posted by EngTech1 View Post
      Nothing Is Fixed : and what the F___ is the Subject Matter Attached to Your Response ?

      Spark Plugs aren't Going To Cut the Mustard Here !


      Glad you go it fixed. I'm sorry I didn't chime in but the email notifications suck since the new website and for some reason I didn't get any notifications from the posts in July. WTF? now I starts to notify me for some reason.
      [/QUOTE]

      My reply wasn't to you so quit posting nonsense. The mani has a bad actuator arm. There is a TSB it will be fixed under warranty. deal with and quit posting here. This is a DIY. There are a million posts about this TSB. Take it somewhere else.
      '09 GTI TSI 11.53@121.18
      '12 TT-RS TBD!

    5. Member onevrsix's Avatar
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      08-16-2011 09:20 AM #55
      Quote Originally Posted by EngTech1 View Post
      Wholly -Poop - This is really BS - there should be a - Giant Recall !

      Labor Rate going to be like $575 + Part - I Think I will Be doing the : Liquid Plastic - Maneuver

      My Miles are all Thruway - with the Cruise Control On - How the Hell could that
      Wear Out - Anything ?
      Liquid plastic isn't going to solve anything. P2015 is indicating that the flaps in you're manifold no longer actuate up, and are stuck open. This happens when the arm on the right of your manifold (looking at the engine from the front) is either disconnected from the nipple or has worn to the point where the nipple no longer grasps the runners. The only solution is a new intake manifold. Can be had for $150 plus shipping if you order form www.1stvwparts.com Part number should be in the original post. Dealer will run you about $220-280.
      The job itself is pretty cumbersome and quite annoying but it is possible with a lot of patients and the proper tools. (small hands help as well) This write up will save you a lot of head scratching. remember to pull the oil filter when removing the manifold. Good luck and Gods speed
      And FYI; steelcurtain was just congratulating me not posting in response to your issue. no need to blow up on him! we're all here for the same reason.

    6. Member EngTech1's Avatar
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      08-16-2011 09:36 AM #56
      Point Being -No One Should have to - Do this DIY - Period !

      Wholly -Poop - This is really BS - there should be a - Giant Recall !

      Labor Rate going to be like $575 + Part - I Think I will Be doing the : Liquid Plastic - Maneuver

      My Miles are all Thruway - with the Cruise Control On - How the Hell could that
      Wear Out - Anything ?


      Seems there are Plenty Of After market Manifolds for Other Tuner Cars and VW
      has always had the lead in Vendor Support !

      No Manifolds Offered to get Rid of the Issue All together !
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


    7. Member onevrsix's Avatar
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      08-16-2011 10:23 AM #57
      Quote Originally Posted by EngTech1 View Post
      Point Being -No One Should have to - Do this DIY - Period !

      Wholly -Poop - This is really BS - there should be a - Giant Recall !

      Labor Rate going to be like $575 + Part - I Think I will Be doing the : Liquid Plastic - Maneuver

      My Miles are all Thruway - with the Cruise Control On - How the Hell could that
      Wear Out - Anything ?


      Seems there are Plenty Of After market Manifolds for Other Tuner Cars and VW
      has always had the lead in Vendor Support !

      No Manifolds Offered to get Rid of the Issue All together !
      I don't think there is a way to 'do away' with the system. fact of the matter is, we're direct injection, carbon build up will first cause the runners to stick, putting more pressure on the nipple on the side of the manifold. eventually the connection to the runner wears smooth and no longer works as desired. We have to many other attachments dependent on our manifold. as you'll notice when/if you tackle the job. FSI does have a manifold that deletes the runners but I don't know how they do away with the CEL. No added benefit in upgrading the manifold as far as gains are concerned. To the above post who referenced a catch can, there functionality has been debated for years now, and ultimately, its found to be unnecessary. (as far as my research has taken me). While the PVC system is filthy and problematic in our cars, its necessary for emissions and better fuel economy. There are images with people who have water/meth injection and Catch Can and their intake ports are still super gummed up after 20k miles.

    8. Member VWRedux's Avatar
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      08-16-2011 12:19 PM #58
      Quote Originally Posted by onevrsix View Post
      There are images with people who have water/meth injection and Catch Can and their intake ports are still super gummed up after 20k miles.

      "There's nothing like a well tuned car on an open road". Paul Newman
      *The New 2011 VW Jetta... At Least You Pay Less To Get Less!*

    9. Member EngTech1's Avatar
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      08-16-2011 02:04 PM #59
      LOL - Haaa Funny Guys , But what the H____ does Meth have to do with
      Hot Oil Vapors ?

      It's the Cooling of these Items that is Dropping them Out of Vapor to be Deposited .

      So Why Not Inject these vapors into the ( Ahead of the High Pressure Fuel Stream )

      Still Lubes the valves without - Coating the Entire Inside of the Intake with Tar !


      Here's an Intake for Ya ! - - Now Look Carefully ans See the Idea !

      http://
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


    10. Member ViRtUaLheretic's Avatar
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      08-16-2011 03:58 PM #60
      Quote Originally Posted by EngTech1 View Post
      LOL - Haaa Funny Guys , But what the H____ does Meth have to do with
      Hot Oil Vapors ?
      The idea was that the water in w/m injection during its flash evaporation stage in the combustion chamber would help steam clean the intake valves.
      As it turns out this hasn't 100% prevented the buildup of carbon deposits on the valves.

      Oh and dude, you need to chill the hell out, all cars have flaws, you cant just flip $hit every time a part fails on your car.
      Especially once you start to add aftermarket parts.
      :APR -stage 2 :BSH -Intake,Mounts,RSB,TB Pipe :Whiteline -A.L.K. :Porsche 17Z BBK
      :Devils Own -DVC-30+Direct Port Injection :BC Racing -BR Coilovers :Flik-FTD :OSIR
      :Eurojet -Ceramic Coated TBE :DEFI :Unibrace :Tyrolsport :Bildon :Hawk :034
      TSI FAQ: http://forums.vwvortex.com/showthread.php?4042736

    11. Member ViRtUaLheretic's Avatar
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      08-16-2011 04:33 PM #61
      Oh and here is something else that should cause a stir with certain individuals.
      I was having a PM discussion with somebody and they mentioned that the stock PCV gases might have a hand in TB failures. This might also pertain to Intake Manifold failures.
      If the PCV gases that are filled with oil vapors and gunk get into the bearings, actuators, and electrical components in the TB and Intake Manifold it could cause premature failure.
      :APR -stage 2 :BSH -Intake,Mounts,RSB,TB Pipe :Whiteline -A.L.K. :Porsche 17Z BBK
      :Devils Own -DVC-30+Direct Port Injection :BC Racing -BR Coilovers :Flik-FTD :OSIR
      :Eurojet -Ceramic Coated TBE :DEFI :Unibrace :Tyrolsport :Bildon :Hawk :034
      TSI FAQ: http://forums.vwvortex.com/showthread.php?4042736

    12. Member EngTech1's Avatar
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      08-16-2011 10:01 PM #62
      Quote Originally Posted by ViRtUaLheretic View Post
      Oh and here is something else that should cause a stir with certain individuals.
      I was having a PM discussion with somebody and they mentioned that the stock PCV gases might have a hand in TB failures. This might also pertain to Intake Manifold failures.
      If the PCV gases that are filled with oil vapors and gunk get into the bearings, actuators, and electrical components in the TB and Intake Manifold it could cause premature failure.

      OK - My Motor is Still Stock - so the vapors I'm Hoping aren't as Bad ( I Hope ) - I'm
      Going to do an Internal Cleaning of Sorts , I'll also be running My Oil a Little Lower 1/4 cup
      on the stick - might help . Just really Hate having - My Hands Tidied , as in Not much One can Do .

      That Catch Can is looking better .
      Maybe I can Just UN-Hook the PVC - Pipe all together , and threw it away ! LOL
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


    13. Member EngTech1's Avatar
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      08-17-2011 06:52 PM #63
      Quote Originally Posted by onevrsix View Post
      Thanks for the heads up

      You Might want to Use this :
      Check Out the 30" special Red Tube .
      http://www.seafoamsales.com/how-to-u...oam-spray.html
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


    14. Member VWRedux's Avatar
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      08-17-2011 09:14 PM #64
      "There's nothing like a well tuned car on an open road". Paul Newman
      *The New 2011 VW Jetta... At Least You Pay Less To Get Less!*

    15. Member onevrsix's Avatar
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      08-18-2011 09:42 AM #65
      Quote Originally Posted by EngTech1 View Post
      You Might want to Use this :
      Check Out the 30" special Red Tube .
      http://www.seafoamsales.com/how-to-u...oam-spray.html
      Yeah, if you look up my created threads, I did a DIY on how to seafoam your car using the caned version. Warning, our cars smoke a lot! I've done it in the past, had cars smoke a decent amount, butThe 2.0T filled my entire driveway after a few revs. Took it out around the block and you couldn't see anything out the back window, it was actually pretty dangerous for those behind me. It was a real smoke screen. I did it twice in one week and the second time was worst than the first. when I pulled my manifold I still had quite a large amount of carbon build up. Next time I have a VAG Comm available I'm going to do it again.
      Quote Originally Posted by VWRedux View Post
      Don't know how I feel about deleting the PVC; If I'm not mistaken the engine relies on the blowby to achieve maximum fuel efficiency. A functional PVC is also required to pass inspection If I'm not mistaken.

    16. Member ViRtUaLheretic's Avatar
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      08-18-2011 11:15 AM #66
      Quote Originally Posted by onevrsix View Post
      If I'm not mistaken the engine relies on the blowby to achieve maximum fuel efficiency. A functional PVC is also required to pass inspection If I'm not mistaken.
      WUT? Dont see how pumping oil vapors into your motor is going to increase fuel efficiency.

      You are correct that the PCV system needs to be intact for inspecation.
      I highly doubt the inspection will go as far to trace a pcv line to determine where it goes.
      Chances are they will pop the hood, realize that the motor has 245724572457 lines running around, check to make sure there arent any noticeable failures, and just close the hood and say all is good.
      :APR -stage 2 :BSH -Intake,Mounts,RSB,TB Pipe :Whiteline -A.L.K. :Porsche 17Z BBK
      :Devils Own -DVC-30+Direct Port Injection :BC Racing -BR Coilovers :Flik-FTD :OSIR
      :Eurojet -Ceramic Coated TBE :DEFI :Unibrace :Tyrolsport :Bildon :Hawk :034
      TSI FAQ: http://forums.vwvortex.com/showthread.php?4042736

    17. Member onevrsix's Avatar
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      08-18-2011 11:22 AM #67
      Quote Originally Posted by ViRtUaLheretic View Post
      WUT? Dont see how pumping oil vapors into your motor is going to increase fuel efficiency.

      You are correct that the PCV system needs to be intact for inspecation.
      I highly doubt the inspection will go as far to trace a pcv line to determine where it goes.
      Chances are they will pop the hood, realize that the motor has 245724572457 lines running around, check to make sure there arent any noticeable failures, and just close the hood and say all is good.
      crankcase vepors often contain majority unburt fuel oil vaports and other gasses.

      Realizing we're direct injection your right its mostly oil vapors
      Sent from my Galaxy S using Tapatalk

    18. Member VWRedux's Avatar
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      08-18-2011 09:39 PM #68
      Quote Originally Posted by onevrsix View Post
      Don't know how I feel about deleting the PVC; If I'm not mistaken the engine relies on the blowby to achieve maximum fuel efficiency. A functional PVC is also required to pass inspection If I'm not mistaken.

      Actually that specialized nipple seen in that thread sucks all the crankcase gases out and runs it post catalytic converter.... and I mean it sucks it out real good with just the right amount of vacuum. When inspection time arrives, connecting up the stock OEM PCV system is a snap! I have spoken with many who have indeed done this and they say it works like a charm!
      "There's nothing like a well tuned car on an open road". Paul Newman
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    19. Member maotsetung's Avatar
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      08-20-2011 12:09 PM #69
      I know this is off-topic but has anyone seen the HEP FSI intake manifold? Looks really good quality and they even have Stage 1,2, & 3. I'm actually wondering if they ever make one for the TSI. Only thing is its a bit pricey but like I said quality is top notch.


      ---
      - thanks,
      - mao

    20. 08-21-2011 10:41 AM #70
      How did you know that you needed to clean your manifold? I don't drive all that often (have less than 10k on my GTI) since I bought my car 18 months ago. I had my first VW service about 1k ago (i dumped and refilled at 3k) and ever since my CEL has come on every few days or so. It's been on and cleared itself at least 5 times now. Is this behavior the kind of thing that prompts a mani/valve cleaning?

      If so, wouldn't I make VW do it, since its under warranty?

    21. Member maotsetung's Avatar
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      08-21-2011 10:49 AM #71
      ^ If you have less than 10K on the clock and barely drive your car..you should be fine. Usually guys do it roughly around 50K-80K and some do it earlier. It really depends on you. You should have someone do a vag-com check on your car to see what's up with cel.


      ---
      - thanks,
      - mao

    22. 08-25-2011 08:26 AM #72
      I'm taking it in to VW today to have them look at it. Of course when I called, they guessed it was emissions related. The CEL came on again last night...i think this makes 6 times now in the last month. I'll let you know if its manifold related.


      Trip to dealership #1
      Dealer said that a sensor was sending a fault - related to evaporative emissions. Tech found it to be the sensor used to monitor intake manifold flapper actuation. Said he tweaked the sensor and sent me home. Of course I knew this wouldn't fix it, but I played their game. The next day, my CEL came on.

      Trip to dealership #2
      Dealer traced the fault to the same sensor and noticed this time that the flappers were sticking. VW replaced the intake manifold with a revised version under warranty. the revised version has lubrication spots that are further away from where the flappers pivot. Supposedly, the previous mani would clog at those lubrication ports and due to their close proximity to the flappers, would cause them to stick. Sounds like a load of bunk, but that's what he said. Also updated the ECQ to increase fuel pressure in the injectors - this is supposed to help as well???

      No CEL since, but its only been about 300 miles on the car.
      Last edited by A3Tripod; 09-18-2011 at 11:32 AM.

    23. Member ViRtUaLheretic's Avatar
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      08-25-2011 09:11 AM #73
      Friend of mine just purchased a media blaster and some walnut shell media.
      We are going to setup an install day and both of us are going to clean out our valves sometime coming up.
      :APR -stage 2 :BSH -Intake,Mounts,RSB,TB Pipe :Whiteline -A.L.K. :Porsche 17Z BBK
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      :Eurojet -Ceramic Coated TBE :DEFI :Unibrace :Tyrolsport :Bildon :Hawk :034
      TSI FAQ: http://forums.vwvortex.com/showthread.php?4042736

    24. Member EngTech1's Avatar
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      08-28-2011 08:45 AM #74
      I'm trying to get a Real Understanding - is all the Technical Data - on this
      PVC System for the - - - 2.0 TSI - VW

      Anyone is this Picture an Exact Design - Or - What It should have Been ?

      Picture of Audi's PVC or FSI's ?

      As I can't seem to find the Filter - Mentioned / The Pic makes it seem PVC has a Filter. This could just be the FSI's PVC system and It's Oil Filter .


      [/IMG]http://
      Last edited by EngTech1; 08-28-2011 at 08:52 AM.
      I'll do My Best to Help You: ** Fall Sale is On ! ** -


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      08-28-2011 12:30 PM #75
      Quote Originally Posted by EngTech1 View Post
      [B] I'm trying to get a Real Understanding - is all the Technical Data - on this
      PVC System for the - - - 2.0 TSI - VW
      Page 25 and 26 here: http://www.vaglinks.com/Docs/VW/Misc...SSP_824803.pdf
      Quote Originally Posted by absoluteczech View Post
      keep it on topic sir
      BT MK6 GTI Build Thread

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