Daniel Noormohamed

Having a small issue with the inlet manifold. theres a small runner to the side of the manifold which is made from plastic its attached to the motor which controls when the flaps open/close.

problem I've encountered is the small plastic notoches on the runner have warn down giving an incorrect reading/pressure within the inlet chamber which results in an engine light.

for a piece of plastic that takes 2min to unclip from just removing the engine cover audi are after £977 for a new inlet manifold and 12hr labour @ £140/hr.

i was wondering if anyone else came up with this problem and what their solutions was.

MP4.2+6.0

Sounds kind of like the vacuum system that controls the intake manifold staging, but perhaps attach a picture since my 4.2 knowledge is back at the prior generation. If it is, there are after market replacement control rods/arms for this instead of the big cost way of replacing the whole manifold.

Daniel Noormohamed

Hi MP.

check this link out. http://postimg.org/gallery/5noi4du0/ its not like you describe. however i wonder if i can fit two inlet manifolds off a 4.2 onto my 4.0 TDi would be a good solution if it was ever possible.

Regards.

mishar

Check this.

MP4.2+6.0

TDI D3's don't exist in North America, and the number of active posters with them elsewhere is sporadic at best. My answer tied to 4.2 V8 petrol, which is the usual U.S. common denominator. Same on other U.S. centric boards like QuattroWorld, Audizine, etc. You might try some Euro oriented boards, though probably then best in Germany.

K9COP

..the expression 'Rest Of World' comes from. Wow.

Speak to Shane at http://www.audi-specialists.co.uk/ at 40 The Causeway, Burwell, CB25 0DU. Pretty sure he runs a TDI A8, so he may be able to help. Good guy.

K9

Mr_Ray

Hi.

I'm also having the same problem with the plastic inlet manifold runner.

what did you do to fix it?

Thanks

Ray

Daniel Noormohamed

Ive not yet fixed it currently using a code reader to clear the code occasionally. What i did was put a small bit of plastic around the worn plastic connectors of the runner to make it correct that works for a while until it slowly slipped off.

searched high/low for a fix including 3D Printing, eBay, scrap yards no one seems to have a 4.0 TDi Audi A8 which is a big bummer really.

It looks as though when i can afford to do so i will need to replace this part via Audi or some Specialist which is a shame really cant be a winner on everything we fix on it haha.

if i come up with a solution before i go to audi i will update you. ive also created a group on facebook https://www.facebook.com/audirepairs?ref=audiworld which i will use to document my findings and repairs i do.

Mr_Ray

I've still not fixed it but come up with a few ideas including 3D printing as I can quickly model the part in 3D

At £1700 I'm going to do a DIY fix

What are you using to clear the code and how long does it last?

Daniel Noormohamed

Hey!.. if you can print it in a 3D printer do the driver side for me and i will happily pay you quite generously.

im using a simple Audi/VW code reader to clear it. the code i clear is part of the engine codes. once i clear its a rocket! while i have the error theres a lot of Lag. bit weird sometimes with the engine light on it has no effect to performance. only a MPG issue. a fix would be the best thing thats ever happen.

In fact you can reprint it at a good price maybe its something we can resell as Audi don't sell the part. try to print with a very strong heat proof plastic that can withstand massive heat and plastic to plastic movement without wearing like the Man-Hummel one has.

Thanks for the response.