Lower inlet manafold replaceent - eeek

[the_IT_bloke]

Engine warning light came on and idling at around 1200rpm but drives ok, took to Audi, the engineer (yes the actual engineer) just phoned me with his diagnostics (they have a late shift);

Having taken some of the inlet mamafold out there is apparently a rod into the lower inlet manafold which has broken. This connects to some valves which allow the air into the engine, (gently) prodding with a screwdriver, these will not move fully to the end stop, may have siezed and caused the rod to snap.

Likely solution; (prices approx)
New lower inlet manafold with all the valves £250 ish
New Vacumn pump £50 ish
Up to 18 new gaskets ranging from 50p to several pounds each
No idea of labour costs, the engineer had never done one before...

Sitting down and breathing calmly now....
I dont doubt the diagnosis, I think Southampton Audi are honest and accurate and ever had an issue with them, however just wanted to run this by you guys.
If it was a computer or electronics I can have it appart, repaired, bebuilt and running like lightning, cars I am not quite so clued up on...

Anyone got any thoughts or had similar experiences?

Looking like its gona cost me in the reqion of £700? :(

Any advice?

[spike]

Hi IT bloke
Can't find it now but sure I read that its fairly common for the intake manifold to carbon up, causing the flaps to stick and fail the (plastic?) link rod. A good independent garage could probably clean out the manifold and fix the link rod - unlike Audi who generally prefer to replace everything (maybe cleaning bits @ £100 / hr does not make economic sense)
The attached link shows how the flap works to vary the intake port area and increase gas speed - click on FSI then stratified to see the flap in the closed position.
Interesting but sorry its not much help to you
http://www1.audi.cn/en/tech/newcar/technology/eng_fsi_hom.html

Cheers Spike

[the_IT_bloke]

Spike

Many thanks for the info. If I am going to spend that much money I do like to know what the issue is, so really useful thanks.

I am going to try to negotiate a discount on the labour and ask for the broken parts, at least I might be able to confirm the diagnosis myself and possible learn enough to do the repair myself if the issue happens again.

Thanks once again for the much needed information.

Paul

[the_IT_bloke]

The continuing saga of the broken piece of plastic in the engine...

Its now been a week and the A2 is still on the ramps.

Apparently one of the 18 gasket / seals which need replacing (if the dealer does the work) as part of the removal and replacement of the lower inlet manafold is on back order.
They doubt I will have the car back till the end of the week now.

On the bright side Southampton Audi have loaned me a new (2k miles on the clock) A6 2.0TDi Tiptronic, fully loaded with all the options from when the A2 went in 'till I get it back. Really nice car, take all the time you need guys ;)

Getting into the FF MMI / Nav / Bluetooth etc. Might have to retrofit one to A2 now :) Thats the problem with getting to play with all the toys, you miss them when thay are taken away :(

[Xiter]

I know the feeling you get from driving a new premium car. But when considering the amount of money between my A2 and the other car, the smile on my face always disappears. Easily. Very easily.

[the_IT_bloke]

Xiter I know what your mean, priced the loaner A6 Avant up at £35k ... :eek:
That and the fact I'm only getting about 30MPG....

2 weeks down and still no A2. I have been told I have the A6 on 'long term loan' and can keep it 'till I have my car back, can everyone please order some A2 gaskets, with luch I will still have it at Christmas ;)

The A6 on the other and is causing me other issues, now everyone at work thinks I got a high spec company car (I do deserve one!) and my director is fending off the complaints.

Ho hum

[bdub]

I am half way through doing mine for same prob. rod not broken on mine but intake filthy with the residue of EGR deposits. I think that is what is making my flaps stick ( oh er mrs ) . Does anyone know if when everything goes back i just reconnect the fuel and turn the key till it starts - or is there a purging / bleeding exercice to go through?

[bdub]

Just completed the strip, clean and rebuild of the lower inlet manifold on the wifes 1.6fsi to clear the fault related to inlet manifold flap 'setpoint not reached'. Cleaned out the lower intake and replaced the flap position potentiometer ( since you can only do that with it off the car, only £40 ) managed to reuse all the gaskets as they were metal and in good nick. Driven to work in it this morning seems fine.