Variable Intake Manifold Links

[PsYcHe]

Nope.. the PF has them too. Slightly different lenghts though.

Not sure if I've heard of the 32v having a problem with breakages though.

[47p2]

Looks like a nice piece of sturdy engineering

Though if Audi had made such a sturdy part it would have cost them an extra 20p per car

[sarg]

What is SSP & WOT???

Statutory Sick Pay

[Adrian E]

Originally Posted by sarg

What is SSP & WOT???

Statutory Sick Pay

WOT usually refers to Wide Open Throttle

Not sure about ssp though - I'm guessing service guidance related?

[AusA8]

Originally Posted by HPsauce

There's certainly been discussion here about that exact topic, but being a D2 driver I didn't study it in detail or recall exactly where it was posted.

Yep, I found them, but being D2 I figured that I'd post up about the D3. Hope that's ok.

Originally Posted by Adrian E

There's threads about these arms in the d2 section, but probably not such a common failure on the d3 yet - nice to see some installed pics too

Thanks.

Originally Posted by 47p2

Looks like a nice piece of sturdy engineering

Though if Audi had made such a sturdy part it would have cost them an extra 20p per car

Definitely sturdy compared to the plastic ones. I took both of them off and the second one broke on me whilst I was studying it in my hands until a gentle bend being applied to it!! . Glad I bought two.

All things relative, they cost me about $70 AUS. I Imagine the Audi engineers saying to themselves, "well here's a way to make money on parts, we'll make a really weak part that can only be fixed by buying a whole new intake assembly". As you say, it would've cost them next to nix to produce a quality part. Seems in complete contrast to the rest of build really doesn't it.

[47p2]

Originally Posted by AusA8

I Imagine the Audi engineers saying to themselves, "well here's a way to make money on parts, we'll make a really weak part that can only be fixed by buying a whole new intake assembly".

I remember when Mercedes redesigned part of one of their door handles, a small metal part which they had been using for a number of years and they had never sold a single spare. The bean counters decided it was over engineered and the part should be made of plastic, suddenly they were selling spare parts and not only that they saved millions of pounds during the time the handle was in production just because the part was cheaper to produce in plastic. Sad but true

[ainarssems]

Quote:
Originally Posted by sarg
What is SSP & WOT???

Statutory Sick Pay
WOT usually refers to Wide Open Throttle

Not sure about ssp though - I'm guessing service guidance related?

SSP- self study programme, there is link to one in the thread below. There is hundreds of them on volkspage.net

http://forum.a8parts.co.uk/showthread.php?t=4368

Looks like a nice piece of sturdy engineering

Though if Audi had made such a sturdy part it would have cost them an extra 20p per car

The problem is that variable manifold flap shafts become stiff and seize because of corrosion. Replacing arms with stronger ones could result in something else braking like shaft. Best solution would be to free the shafts, lubricate with anti-corrosion grease and replace plastic arms.

Am I right it's only the 40-valve engine in the D2 that use these?
(I'm PF 32-valve and "managing" with "only" 340hp

32V has only one as it has 2 stage manifold instead of 3 stage on 40V. Does not seem to give problem on 32V. My guess would be that on 32V engine more oil from engine breather system gets in intake and lubricates it sufficiently to prevent corrosion and sticking. At least manifold on my car was fairly oily inside when I had it off.

[AusA8]

Originally Posted by sarg

What is SSP & WOT???

Statutory Sick Pay

As quoted previously and by ainarssems, WOT is wide open throttle and the SSP is the self study program that Audi issues to all of its tech's as part of their training.

Originally Posted by ainarssems

The problem is that variable manifold flap shafts become stiff and seize because of corrosion. Replacing arms with stronger ones could result in something else braking like shaft. Best solution would be to free the shafts, lubricate with anti-corrosion grease and replace plastic arms.

Whilst I agree with you, the plastic shafts and flaps are not the issue, it's the build up on them - especially the carbon build for FSI engines. Sometimes the bearing on the manifold are to blame also. They are easy to clean up, but pulling apart the assembly and reinstalling is not an easy task as there is a 'blind' fitting at the rear that can cause all sorts of issues if it's not placed correctly and I note that Audi Aust won't clean them either! From my point of view, the movement was not restricted, hence the linkage simply failed.

[Nollywood]

I've had the same issue on my '01 S8. I did think of the metal Gruven items, but I would imagine the OEM parts are plastic for a reason. To protect the internals.

If the shafts are seized, the plastic arms would break. If these arms are metal, something else would break (internally, and more expensive). In my opinion, the aluminium arms would only serve to mask an inherent problem. Don't under estimate the force those vacuum units exert. If the shafts or flaps break internally, the engine would swallow the bits.

I had 20 made for me, from a less-brittle plastic, as durable as the originals. These too would break, if the shafts were seized in the bushes. These are available for any interested parties.

http://forum.a8parts.co.uk/showthread.php?t=4210