Audi A5 3.0TDI air manifold intake

randel · 06-09-2012 10:05am #1

Engine light has been on for the last 2 months. Eventually had it checked by the dealers. Turns out I need the manifold on the right hand side replaced. They also recommend getting the left side done too. I have just had it serviced and also had a wheel bearing replaced so I am reluctant to hand over another 1500 euro to the dealers. I have given them enough at this stage!!

I have read on another forum that a few other 3.0 tdi owners have removed and cleaned the manifolds on their cars themselves. I am pretty handy with DIY and have replaced a few simple parts on the car by myself so I would like to take this job on.

Would anyone with any experience doing this be kind enough to give me a brief (or detailed) step by step guide to removing and cleaning the manifolds? with pictures would be even better.

Id really appreciate it.
Thanks in advance.

Ronnie Beck · 06-09-2012 2:47pm

http://forums.tdiclub.com/showthread.php?t=157948

http://pics2.tdiclub.com/gwillie/VW/Sballintake/INTAKEMAN101b.htm

I used these guides to clean out mine. I have a 2.5 TDI. Its an inline 5 but I'm guessing you just have twice the work. The biggest headache is the bolts. Get the proper tool to remove them. Access might be limited. Stick it in and out of the head a few times wiping off the dirt each time. This allows the key to sit correctly into the bolt head. Apart from that just do everything slow and gentle so you don't knock any crap into the cylinders. Nissan doctor done a write up on here before too. He used a hoover to suck up any lose coke.

Also investigate blanking your EGR. This is the cause of the problem especially if you do alot of urban driving.

Good luck. Its worth it in the end. Lots more power.

deandean · 06-09-2012 3:25pm

Getting it off will be the hard part.

Here is a linky to a guy who has special kit for cleaning inlet manifolds, EGRs etc

http://www.bmw-driver.net/forum/showthread.php?t=37545

AzureAuto · 10-09-2012 6:46pm

Im assuming it is the runner rail in one of the inlet manifolds that has failed? Hence the engine management light. Whether you get the dealer to do it or choose to do it yourself, the part will have to be got through the dealers as far as I know. They're awkward enough to do.

randel · 31-12-2012 4:17pm

Just to let you guys know, that I replaced the manifolds myself. I purchased two reconditioned ones on ebay and spent 5 hours fitting them yesterday.
Not an easy job but can be done if you're relatively handy. The best thing was when I started the car this morning and the "check engine" light had disappeared. Great after 5 months of looking at it!
Found this webpage very handy http://www.vwaudiforum.co.uk/forum/showthread.php?137123-Intake-Manifold-Replacement-and-Fix-2-7-TDi-3-0-TDi-V6-Engines

Reckon I saved myself the guts of 1000 euro doing the job myself.

Audi A5 3.0TDI air manifold intake

Comments