TSI Intake Manifold Removal DIY + Valve Cleaning

[tampa_mk5]

But you can't go wrong with the GM cleaner though. Great stuff. I didn't even use a whole can.

X2

[skibi]

I'll second on GM cleaner....
Took me about 8 hours to clean those ports. Do NOT want to do it ever again....

[MMMH2O]

Had the intake manifold replaced in August after getting the CEL (P2015). Drove it and had worse gas consumption...24 mpg on Tiguan vs previous 28 mpg. Had several engine fault warnings out on a trip in Wyoming. Took it to the dealership in Casper and they thought it was bad wiring to TB. Read where you need to do a TB reset after disconnecting the battery. I did that by inserting key in ignition and turning to Accessory position, holding down the pedal for 2 minutes, turning key to off, and restarting. Resets 0 to 100% TB setting in computer. Now back to 28 to 30 mpg on highway driving. Two cents..do the free reset and see if that helps.

[dougfalk]

So i drive a 09 CC with a TSI and i've had a cold start rough idle and misfires that have been getting worse. After changing the plugs and coils i took it to my mechanic and he did an injection cleaning AND after that didn't work he replaced the injector. I was getting the P0302 code. This didn't help either so i decided to take it home and scrub the valves even tho he said that they were fine. What i found when i got the intake manifold off was that the injector he replaced was the second from the left.

I have 3 questions.

for the P0302 code, should he be replacing the one he did or the one on the right as i believe the firing order is 1-3-4-2?

The new injector is the only injector that came out of the engine block. Do i need to buy a reseal kit for that injector?

Should i replace the other injector while i have the manifold off?


I'm planning on finishing the job this afternoon.

[dougfalk]

So i drive a 09 CC with a TSI and i've had a cold start rough idle and misfires that have been getting worse. After changing the plugs and coils i took it to my mechanic and he did an injection cleaning AND after that didn't work he replaced the injector. I was getting the P0302 code. This didn't help either so i decided to take it home and scrub the valves even tho he said that they were fine. What i found when i got the intake manifold off was that the injector he replaced was the second from the left.

I have 3 questions.

for the P0302 code, should he be replacing the one he did or the one on the right as i believe the firing order is 1-3-4-2?

The new injector is the only injector that came out of the engine block. Do i need to buy a reseal kit for that injector?

Should i replace the other injector while i have the manifold off?


I'm planning on finishing the job this afternoon.

I went through and replaced the combustion chamber ring (white ring) on the injector, cleaned the valves and voila! Car runs exceptionally well. Thanks for the DIY steelcurtain! Wouldn't have been able to tackle it without it!

[steelcurtain]

I went through and replaced the combustion chamber ring (white ring) on the injector, cleaned the valves and voila! Car runs exceptionally well. Thanks for the DIY steelcurtain! Wouldn't have been able to tackle it without it!

Awesome! I flagged your post yesterday to follow up this morning; glad to see you worked it out. I think it is safe to say that if you pull the mani and the injectors come out of the head, then the seals are bad.

Amazing this DIY still hasn't been sticky'd by the vortex mods. This is the only VW forum that hasn't and it's the only DIY available IIRC.

[ViRtUaLheretic]

Ive been trying to get the TSI FAQ stickied for how long now?

[dougfalk]

Awesome! I flagged your post yesterday to follow up this morning; glad to see you worked it out. I think it is safe to say that if you pull the mani and the injectors come out of the head, then the seals are bad.

Amazing this DIY still hasn't been sticky'd by the vortex mods. This is the only VW forum that hasn't and it's the only DIY available IIRC.

Definitely needs to be sticky'd. And with the amount of people having this issue, it's shocking that my VW/Audi mechanic and the dealer didn't feel like the valves were a potential issue. I'm just glad it's done with... for now...

[MK6GTI]

This should definitely be stickied... especially due to the number of people this helped out.

[steelcurtain]

This should definitely be stickied... especially due to the number of people this helped out.

[zrickety]

Thanks for the great how-to. My 09 goes in to the dealer tomorrow, they say this manifold swap will take all day. But covered under powertrain at 49k, so I'll let them do it. I just hope the latest revision lasts longer than this.

[steelcurtain]

Thanks for the great how-to. My 09 goes in to the dealer tomorrow, they say this manifold swap will take all day. But covered under powertrain at 49k, so I'll let them do it. I just hope the latest revision lasts longer than this.

Thanks man. I recommend you clean the valves while they are replacing. probably won't be covered under warranty though.

[ifhn166]

I have a 09 CC with 73K miles. Recently I've been experiencing a rough idle on a cold start & CEL. The mechanic said it was a misfire. Replaced ignition coils & did a fuel system cleaning. Ran fine for about a day and same issue started again. Back to the shop. Replaced spark plug in cylinder 4. Ran fine for about a day and same issue started again. Back to the shop. Replaced all the spark plugs. Ran fine for about a day and same issue started again. Diagnosed a leak on the intake manifold at cylinder 4 and a bad sensor on the manifold. Replaced intake manifold, gasket & cleaned the valves. Still had a rough idle at start. Further diagnosis indicated that the fuel injector 4 was not working properly. So they tore it apart again and replaced the fuel injector. Rough idle at start & CEL was back after two days. Misfire in cylinder 4. The misfire goes away after the engine warms up. Injector tested fine. Replaced spark plugs with a different brand. Still misfiring on a cold start. They smoked tested it. Ignition coils are performing as expected. Lastest news is that the car is losing a few pounds of fuel pressure from the high pressure mechanical fuel pump.

[Mad09Tig]

This is a really nice write up. Thanks steelcurtain! I bought my Tig 2 years ago used with 15k on the clock. At about 24k I got a epc fault and took it in. I got a lot of the same bs most of you did. "We cleaned the intake manifold, it has carbon build up yada yada. 2 times after that they replaced the intake manifold. This was around 28k. Reflash and 50k later I'm at 73K and I just got the intake manifold flapper fault. Getting my mani in Friday and I would like to fix it over the weekend. Sucks that this design is so poor and the only fix VW has is to sell the manifold for cheap. I wish that catch can setup was cheaper cause that would be nice to have. I have to check my tool box but I think I already have a few triple square tools in there from past projects. I like my VW but I dont like the thought that I will need to do this fix every 30 to 50k.

[steelcurtain]

Thanks man. I thought they got that issue fixed
With updated manifold? You could delete the flappers and trick the actuator so no cel. But that's more involved and may have worse cold start issues.

[gsprobe]

Hey all- Thanks for this thread!! What could prevent a full teardown and cleaning?

A catch can installed when new? Seafoam?

I really don't want to take apart the intake and head to manually scrape the pistons and valves while parked in my office parking garage

[steelcurtain]

^ nothing really due to the return gases from EVAP. CC's and meth help do does seafoam but it will still buildup and need to be removed at some point.

You don't have to pull head and scrape pistons. Lol. You Just habe to follow this DIY.

[passatjim]

I followed the steps outline on this forum but for some reason I can't seem to pull the manifold off of the engine. The only thing that I have not taken loose are the fuel sensor and the valve on 1 &2.

I thought if I could pull the man out a little ways it might be easiler to do.

I can rock it up & down but can not pull it straight - (even tho it will allow me to pull out just a little.

I can't seem to see the problem. could those two item cause this. They look like they are connect to the main unit and would come off all together.

If any one has a ideal I would be most graftful!

[ViRtUaLheretic]

I followed the steps outline on this forum but for some reason I can't seem to pull the manifold off of the engine. The only thing that I have not taken loose are the fuel sensor and the valve on 1 &2.

What do you mean valve on 1 & 2?
Did you disconnect the fuel hardline?

Did you remove the support brace from under the manifold?
Upload some pictures.

[Mad09Tig]

Took a lot of tugging and pulling but I got my manifold off. Only problem was 2 of the fuel rail bolt sleeve got broken off and I damaged a o-ring some how. I had put it back together and it was leaking fuel like crazy. Just ordered a new fuel rail and o-rings. I thought it was going to be simple but at least I'm getting my hands dirty!

[steelcurtain]

Took a lot of tugging and pulling but I got my manifold off. Only problem was 2 of the fuel rail bolt sleeve got broken off and I damaged a o-ring some how. I had put it back together and it was leaking fuel like crazy. Just ordered a new fuel rail and o-rings. I thought it was going to be simple but at least I'm getting my hands dirty!

Learning the hard way happens to all of us. Sorry to hear about your misfortune.

[Mad09Tig]

Oh it's all good. I haven't worked on a car since my old Honda back when I was swapping motors and clutches. I got a few scratches from working on the VW and I actually smiled at them cause now we are really becoming one. I know that sounds crazy but I don't like other people touching my car still. If I mess something up I dont have anyone but myself to blame.

[siegfried]

steelcurtain, how many miles did you have on your GTI when you cleaned the manifold?

[steelcurtain]

steelcurtain, how many miles did you have on your GTI when you cleaned the manifold?

Around 50-55K IIRC.

[EngTech1]

Thanks man. I thought they got that issue fixed
With updated manifold? You could delete the flappers and trick the actuator so no cel. But that's more involved and may have worse cold start issues.

Trick the Actuator - How So ?

Delete the Flappers - How So ?

Please use Detailed - Technical Info , thanks .

[steelcurtain]

Trick the Actuator - How So ?

Delete the Flappers - How So ?

Please use Detailed - Technical Info , thanks .

I wish I knew the details as I would post them up. I know it can be done since APR and USP has done it.

[EngTech1]

So I never hear of the Guys with Vag - Chiming - in saying ; Oh Ya We corrected that !

Do they even have a way to Set - ECU into - Ready Mode , so one doesn't have to Drive
The Dam Car : 80-100 miles to see If What did
Worked to correct the Issue - ?

[hightechrdn]

Yes, one can clear stored faults/codes using a VAG-COM unit. You can also use of a million different OBD 2 devices or even the cruise control stalk buttons if you have an APR ECU flash. I believe APR and other tuners are modifying the ECU flash, not using a VAG-COM type setting change to avoid a CEL with the intake flapper removed/deleted/disabled.

Forgot to add... Are you trying to clear codes or set the emissions checks to the ready state? Forcing the emissions checks to ready isn't generally available to the public as it would be a clear violation of the various EPA, Federal, and State emissions laws. Besides trying to pass an emissions check why would forcing the checks to ready be such a big deal to you?

You keep going on and on about the intake manifold code and readiness checks/clearing codes in every post that you make, even when the thread isn't about those subjects. Sorry to call you out publicly, but your posts are really getting old. If you are that upset about the intake manifold issues, call VW!

[hightechrdn]

So I never hear of the Guys with Vag - Chiming - in saying ; Oh Ya We corrected that !

Do they even have a way to Set - ECU into - Ready Mode , so one doesn't have to Drive
The Dam Car : 80-100 miles to see If What did
Worked to correct the Issue - ?

Sorry if I wasn't helpful in my previous reply... Look in the VAG-COM sub forum on this site. There is a thread describing how to set emissions readiness checks using the Rosstech VAG-COM HW/SW. I didn't check into all of the details, but is looks like it is viable for quite a range of models and years. Not sure why you need to do so, unless you have an inspection coming up, but hope that the information helps.

Thanks

[EngTech1]

Yes, that is a Nice - Write Up !

A Few Pic's would have been Super Good .


Well I think I found a Way to Lick the ECU - ( Get Ready ) were going to Screw You for
$59.95 for a 1 Time Push the Button at VW - Another $89.95 to tell You what Wrong , and then We'll
Charge You what Ever to Fix - It - BS .

I Simply Soaked and Sprayed the - H - out of the Intake & Flapper Valve Controller &
Vacuum Lines : No Codes - Go get Inspected !

OK, Thanks for Your - Input - CEL with the Intake flapper removed/deleted/disabled.
Understood about NOT AVAILABLE to PUBLIC - is total BS - IMHO .

Hears Why If one was to due that - It could be Flagged as done in last 20 Days - a Clock Mode
Allowed or Not allowed .

General Public is Being Forced to Go Dealer , then the Dealers are Abusing this Power and making all kinds of Request for Repair or to Simplify Not Passing the Car -
Unless You Dump around $200.00 in Their Pockets .

[EngTech1]

OK , but I hadn't heard If it was Fixed !

Anyway - I took some Cleaner - seems like strong stuff, and did the Manifold and Vacuum Lines .

Got the ECU to do a reset to ready , Long enough to get Inspected .

Now it seems I also have a E-vap - Hope that's a Fuel Cap ?

Maybe there's a way to Burn that - Out - Vaporize It : lol

Any Idea's much appreciated , Thanks

[siegfried]

OK , but I hadn't heard If it was Fixed !

Anyway - I took some Cleaner - seems like strong stuff, and did the Manifold and Vacuum Lines .

Got the ECU to do a reset to ready , Long enough to get Inspected .

Now it seems I also have a E-vap - Hope that's a Fuel Cap ?

Maybe there's a way to Burn that - Out - Vaporize It : lol

Any Idea's much appreciated , Thanks

You write - Funny !
Can't Help you - Sorry

[EngTech1]

My Engine sounds Better Now - I Think ?

http://www.youtube.com/watch?v=hxJ2Ok_X8iM

[EngTech1]

Anyone throw up a E-Vap Diagram - would be Appreciated , Thanks

[ViRtUaLheretic]

Anyone throw up a E-Vap Diagram - would be Appreciated , Thanks

file is legit
http://www.2shared.com/complete/TTTn...803_20tsi.html