Intake manifold inside
 

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may be use full to some one i had no luck fixing it yet think i will make a sleeve on the lathe out of brass or bronze

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thats what i used to un do it all

Thanks for the post Guy. If you come up with a solution please post here and I will add it to the sticky.

im working on it i have taken mesurements and used a vernier calliper ect.. just working on a plan and if they work i may make quite a few up and stock them i will guinea pig the inserts out on myself for a few weeks and then offer them up on the forum for people to fix the same problem :-) if thats ok

+++:D

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oh yea thats a 40valve head by the way just came across it thought id put it hear

i will soon be offering a repare service for the intake manifold problem i have been working on it for a while now and have made brand new components out of self lubricating PTFE and they are coming on great much much more freedom for the components to operate i belive this will also solve the problem of broken linkages for people too as the movement has been improved ten fold is it true that audi will not repare an intake manifold but instead sell you a new one at the cost of £700 ? or have i heard that wrong ? many thanks i will soon post up some pictures

Hi Guy,

The problem awaits all of us sooner or later so I'm very excited to read about your solution.

Thanks.

i will offer a service i will stock 2 manifolds that are referbished and do a trade in policy new for old and that way there is no waiting for people you can be back on the road in 24 hours :-)

well what do you think would be a good price that people would be willing to pay for a referbed intake manifold ?

this will include a butterfly valve service
egr valve strip down ad clean
torque valves repare and uprated bushings
Ptfe inserts for the main shaft
and of course a jolly good clean up to rid of the exsess carbon build up that you get

i think a new manifold is close to 600 if not more and as far as im aware there is no service offered at the moment for restoring a complete intake manifold

thoughts ?
prices ?

and of course any body want to place an order ? first 5 will get a 20% discount on what is decided to be the price with your help of course its been a long time coming but now its been developed i can now offer this service +++

being a V6 owner (and therefore impartial!) might I suggest the exchange is supplied with gaskets? Nothing worse than having to mess about with grotty old gaskets and risking leaks when refitting!

sorry i forgot to mention it will have a new gasket for refitting. +++

excellent work Guy, can you please post some pics of the replacement parts.

I found a thread on quattroworld where a guy did a similar solution but a bit more extreme, he machined the intake flap shafts.

http://forums.audiworld.com/forumdisplay.php?f=8

i could not find it with your link Goran maybe you can go on the thread itself and post the link to that, yes i will post up some pictures when my phone is back from car phone it had a software problem so its being fixed and im using an old school Nokia at the moment

sorry, that looks like the wrong link it says audiworld, oops.
hope this one works.

http://forums.quattroworld.com/a8/msgs/181.phtml

simmilar to what i have done but i have made them with PTFE and made the whole thing from scratch rather than making an insert for what was there i have made the whole thing and press fitted it on and used a bonding agent that withstands high temprature, and i have also made new inserts for the other end bushings and that combined has made the movement so free that there will never be any excess strain to cause the linkage to snap, i will offer a full warrenty with my service, i will try my best to get some pictures together for you to see.

also if any one would like to place an order with me or for any more info PM me
or
daviesbike@yahoo.co.uk
07776246886

hopefully when its sorted mike may well make it a sticky if i start a new thread offering the service +++