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  1. #1
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    EGR / intake manifold removal & clean 170 BMN engine

    Just completed strip down & clean of my Audi a3 sport back 170 bmn egr valve & intake manifold
    Gaskets used
    03G1311547
    N90978701
    0691311547D
    O3G129717C

    What an utter **** of a job! This engine must have been designed by an utter halfwit! It starts off easy enough. Removal starts from bottom working upwards. First remove the lower air incoming pipe with a clip that pulls off. Lower the hose down. Next remove the anti-shudder valve + wiring. Then remove the egr valve + wiring. Then remove the manifold itself including the hidden bolt inside the neck of the manifold. Why oh why design all the bolt heads facing downwards for the egr valve & anti shudder valve?...and some that are near on inaccessible?

    My egr valve wasnt actually that bad but the manifold was caked in oil / soot residue. Absolutely disgusting. I ended up filthy when I'd done.

    Ended up breaking the clip on the plastic vacuum valve solenoid + the clip on the dipstick tube. Both made from crap plastic + now need replacing.


    To be honest half this engine & associated gubbins is made of plastic with poor access unless you have the handS of a small Asian child. I've hardly any skin left on my knuckles...and due to the poor access tools end up falling down in the engine so you have to remove part of the lower engine cover to retrieve them.

    I work in heavy engineering & to be honest im less than impressed with the design or engineering of the engine. Access is poor + hell of a lot of part are made from plastic. I can see this being my first + last Audi. At the side of the two Subaru's I've had before I'm not that impressed with the design of the engineering or access for maintenance.

    Pretty gutted... my dream car has turned out to be a poorly designed money pit! (Up to now new- battery, alloy wheel, dual mass flywheel / clutch, injectors, & now needs a turbo) :-(

    Overpriced junk im afraid.

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  3. #2
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    Just to add after seeing the rubbish & debris ive just scraped out of my intake manifold the following article below doesn't suprise me one jot.......have a read!
    German cars lose out in reliability survey - Telegraph

  4. #3
    Lewis583's Avatar
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    Could be worse. You could have needed to remove the cylinder head and all valves for a thorough clean out like I had to recently on a MINI Cooper SD. Now that is a messy job.
    2008 E92 BMW 335i M-sport
    1990 Golf GTi w/ a 20v heart BUILD THREAD
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    2006 A3 2.0T quattro S-line R.I.P. You will be missed.

    ** Breaking - 8L 1997 Audi A3 1.8T. **

  5. #4
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    To be honest half this engine & associated gubbins is made of plastic with poor access unless you have the handS of a small Asian child. I've hardly any skin left on my knuckles...and due to the poor access tools end up falling down in the engine so you have to remove part of the lower engine cover to retrieve them.

    I work in heavy engineering & to be honest im less than impressed with the design or engineering of the engine. Access is poor + hell of a lot of part are made from plastic. I can see this being my first + last Audi. At the side of the two Subaru's I've had before I'm not that impressed with the design of the engineering or access for maintenance.

    you want to try work in the Aerospace Engineering industry on Typhoon or Tornado, you'll soon discover that there is plenty of room in a cars engine bay

  6. #5
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    Quote Originally Posted by JimmyH View Post
    you want to try work in the Aerospace Engineering industry on Typhoon or Tornado, you'll soon discover that there is plenty of room in a cars engine bay
    Used to work for an aero engine parts manufacturer.....fuel injection / combustion turbine blades / bearing rings.....and no crappy plastic that ends up with hot / cold brittleness involved there!

    Fair enough your plane might have limited access but did you bring half of the electrical plastic components back out with you as you removed your arm? I bet not!!!!

    Going back to what I orginally said why would you design parts that are screwed in UPWARDS with low torque tightness? If they become loose they fall outwards with gravity!!!! Seems a bit 'Heath Robinson' to me.
    Last edited by Bedders; 20th November 2013 at 16:02.

  7. #6
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    Quote Originally Posted by Lewis583 View Post
    Could be worse. You could have needed to remove the cylinder head and all valves for a thorough clean out like I had to recently on a MINI Cooper SD. Now that is a messy job.
    Id love to know what percentage of modern diesels (of all brands) are literally giving themselves the car equivelent of coronary heart disease?

 

 

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