so a bit of coin flip between fitting the BKD manifold which is the cheaper option but not sure how and what the procedure would be or biting the bullet and getting a replacement and get that fitted....added to the dpf issue and having that smashed out and remapped im looking at quite a hefty bill ..well done VW another fine mess you got me into :/
A3 2.0 tdi inlet manifold
- Thread starter NEILGF
- Start date
As an update to this thread I have potentially sourced the required seal, albeit an upgraded more heavy duty part to resolve the issue, along with the other parts required to modify & upgrade the flap linkage, the parts will come in at the grand sum of £10-£15 to rectify the issue! If the weather holds off this week I'll be fitting my improved manifold to the car & can give some proper feedback on how it works.
As this will actually be my '2.0' modification to the manifold and the last attempt was a real basic repair that's lasted 2yrs+ I'm pretty confident I'll have a much more permanent fix... Defiantly better than buying a new manifold too
As this will actually be my '2.0' modification to the manifold and the last attempt was a real basic repair that's lasted 2yrs+ I'm pretty confident I'll have a much more permanent fix... Defiantly better than buying a new manifold too
As an update to this thread I have potentially sourced the required seal, albeit an upgraded more heavy duty part to re parts required to & upgrade the flap linkage, the parts will come in at the grand sum of £10-£15 to rectify the issue! If the weather holds off this week I'll be fitting my improved manifold to the car & can give some proper feedback on how it works.
As this will actually be my '2.0' modification to the manifold and the last attempt was a real basic repair that's lasted 2yrs+ I'm pretty confident I'll have a much more permanent fix... Defiantly better than buying a new manifold too
That would be awsome looking forward to your write up
)
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I didn't run for long without the swirl flaps on, had the DPF taken out and a gentle map, which totally transformed the car. I think that the swirl flaps and the DPF are a terrible mix and ruin the car.
Wilky where did you get you dpf done ? Was the work any good ? Ive been quoted various amounts with the remap think to about 200/220 bhp ..cant remember .
Not yet, I haven't managed to get any time to refit the manifold, in the meantime I've noticed a part which really needs some work or modification to bolster the repair so I'm on the hunt for another seal/ bearing to complete the job. Even with the extra part the cost will come in sub £20 for the bits needed.
I have this badly worn manifold the the swirl flap rod exits too. It is spitting all sorts of oily gunk all over the left hand side of the engine bay. The cabin now stinks of diesel and recirc gasses and I'm sure it must be bleeding away the turbo pressure also (at least on no. 1, as gas pours round the worn shaft). This afternoon I am planning on removing the whole shaft, tapping the exit hole and sealing it with an appropriate bolt. I have just realised that if i do this I will effectively leave a channel between all the inlets where the bushes that the shaft ran in used to occupy. This will have an effect on the gas flow and pressure at any particular inlet, as as the inlet valve opens pressure will reduce on the other three inlets. (albeit they are not yet open and the turbo is still supplying pressure.) It seems to me that the turbo will then be having to do a bit more work as it is having to pressurise what in effect is a larger chamber?
I guess my question is this: has anyone made a similar modification, i.e. removal of the whole shaft, and can they please give me the any feed back, both on the method of removal and the resulting effect on the performance of the engine.
Thank you
I guess my question is this: has anyone made a similar modification, i.e. removal of the whole shaft, and can they please give me the any feed back, both on the method of removal and the resulting effect on the performance of the engine.
Thank you
I just changed the inlet on my 57reg 170 also. I'd not noticed any major driving issues (apart from sluggish throttle at low rpm), but noticed oil/soot/leak near the cambelt above the alternator where the swirl flap shaft had worn. The flaps also weren't working so stuck open.
I sourced an alloy inlet with flaps from a breakers, in really good condition (part no. 03G 129 713H). The H means it has the swirl flaps.
My plastic inlet was really gunged up, (as was the EGR and ASV, so cleaned them both up). As others have said, the alloy inlet fits straight on (the top 5 long bolts are the right size (one hidden inside the inlet opening), only the lower 5 bolts need to be a bit shorter so I bought some 10mm shorter bolts for pence from a local nut and bolt shop).
The two metal brackets fit of sorts; the bracket that holds the dipstick/swirlflap solenoid holder I just used the one top bolt (the lower bolt might work if a spacer was used to bridge the gap to the head) but after bolting it to the dipstick it sits fine. The other bracket which holds a bit of wiring loom also would need grinding or bending to clear a casting rib but minor modifications to sort.
Other parts I got;
Manifold to engine gasket part no. 03G 129 717D (D means metal gasket which is suitable for alloy inlet)
EGR to manifold gasket part no. 03G 131 547C
EGR to pipe gasket part no. 069 131 547D
ASV to EGR N90978701 seal
I sourced an alloy inlet with flaps from a breakers, in really good condition (part no. 03G 129 713H). The H means it has the swirl flaps.
My plastic inlet was really gunged up, (as was the EGR and ASV, so cleaned them both up). As others have said, the alloy inlet fits straight on (the top 5 long bolts are the right size (one hidden inside the inlet opening), only the lower 5 bolts need to be a bit shorter so I bought some 10mm shorter bolts for pence from a local nut and bolt shop).
The two metal brackets fit of sorts; the bracket that holds the dipstick/swirlflap solenoid holder I just used the one top bolt (the lower bolt might work if a spacer was used to bridge the gap to the head) but after bolting it to the dipstick it sits fine. The other bracket which holds a bit of wiring loom also would need grinding or bending to clear a casting rib but minor modifications to sort.
Other parts I got;
Manifold to engine gasket part no. 03G 129 717D (D means metal gasket which is suitable for alloy inlet)
EGR to manifold gasket part no. 03G 131 547C
EGR to pipe gasket part no. 069 131 547D
ASV to EGR N90978701 seal
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Thinking about changing to metal manifold is it worth it? thanks
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Did you get round to swapping the BKD one in? Another guy on the forum is discussing the same issue.
