1.6 FSI BAD Inlet Manifold removal

Quill

Member
Hi, I'd very much appreciate a bit of help on removing the lower part of the inlet manifold. I've removed the upper (main) part of the manifold but the lower part doesn't seem to want to come free although all the bolts and wiring loom/connectors have been disconnected (I'm working off the Audi maintenance manual instructions). The lower part can now be moved a bit and I'm wary of breaking something if I force it.

Is it normal to have to apply some brute force? Is there any risk of breaking the inlet manifold flaps/actuators that are fitted to the lower part of the manifold. Can anyone tell me why it won't shift. From the diagrams I have it seems the injectors can't be the problem but it's difficult to see. From the feel of it I'd say it isn't the locating pegs between the lower manifold and the head either.
 
I would say its because its stuck on the injectors--they mount onto the inlet as the inlet forms the fuel rail. Remember when assembling to use new injector tip seals and the seals to the manifold. the flaps will protrude slightly into the block so be careful and ensure the manifold locates on the dowels when assembling or the flaps will foul and its back off again. Good luck -braver than me i just watched when i had my injectors failed many years ago. mike
 
Hi a2sumo,

Thanks for your advice - I had forgotten that the fuel rail is in the lower manifold - so the O rings on the injectors will be holding onto the manifold. The resistance feels like O rings too. I'm only intending to swap Injector 4 to cure a misfire, plus a general cleanout of the inlet area. I've replaced the tip seal and O ring on the injector that's going to be fitted - so thanks for your reminder to order the O rings on the other 3 as well.

Hi steaman,
Thanks for the video link.

Regards

quill
 
Hi folks I'm in the middle of replacing my inlet manifold and the seals that go on the end of the injectors and on the end of the brass fitting don't look good, anyone got the part numbers for new ones? I think there are 12 seals all together that go on. I'm not removing the injectors . Is it an Audi only part or is there an alternative make that's good and quick to obtain? Many thanks
 
3 and 4?
3 and 32 seems to be sold together.

1581874643331.png

1581874689370.png
 
Hi folks I'm in the middle of replacing my inlet manifold and the seals that go on the end of the injectors and on the end of the brass fitting don't look good, anyone got the part numbers for new ones? I think there are 12 seals all together that go on. I'm not removing the injectors . Is it an Audi only part or is there an alternative make that's good and quick to obtain? Many thanks
Hi, It's a long time since I did mine, so I'm a bit rusty on the details - I'm not sure what you mean by "the end of the brass fitting".
Each injector has 2 identical O ring seals, one to seal the aperture at the "head" end and the other to seal the aperture where the injector fits into the fuel gallery in the inlet manifold. I was told that any injector O ring seals that had been disturbed should be replaced - so in your case (having removed the inlet manifold) you would need 4 new replacements. I bought them from a local Bosch agent for about £5 each ( I guess any garage that specialises in fuel injection systems would be able to get them).

BTW I'm about to scrap my 1.6 FSI A2 (It's on Ebay/Gumtree - too many engine related problems to fix). I can take off a few easily accessible parts if anyone wants them (eg rear window winder handles and the corrugated EGR pipe)

Regards

Quill
 
Thanks for the info. The o rings I'm looking for are on the other side of the manifold, I'll take a photo in a few minutes cheers
Here's the side of the manifold with the brass connectors in
IMAG0844.jpg

You can see I've removed one brass connector

Here's the connector 2 rings one hard one soft

IMAG0845.jpg


Inside is another that goes on the end of the injector

IMAG0848.jpg


Pretty poor condition

IMAG0851.jpg


Cheers
 
Hi, It's a long time since I did mine, so I'm a bit rusty on the details - I'm not sure what you mean by "the end of the brass fitting".
Each injector has 2 identical O ring seals, one to seal the aperture at the "head" end and the other to seal the aperture where the injector fits into the fuel gallery in the inlet manifold. I was told that any injector O ring seals that had been disturbed should be replaced - so in your case (having removed the inlet manifold) you would need 4 new replacements. I bought them from a local Bosch agent for about £5 each ( I guess any garage that specialises in fuel injection systems would be able to get them).

BTW I'm about to scrap my 1.6 FSI A2 (It's on Ebay/Gumtree - too many engine related problems to fix). I can take off a few easily accessible parts if anyone wants them (eg rear window winder handles and the corrugated EGR pipe)

Regards

Quill
Cheers I'll try some local places tomorrow.
 
Nod - There's some useful information and part numbers in this thread:
 
Here's the side of the manifold with the brass connectors inView attachment 61480
You can see I've removed one brass connector

Here's the connector 2 rings one hard one soft

View attachment 61481

Inside is another that goes on the end of the injector

View attachment 61482

Pretty poor condition

View attachment 61483

Cheers
Hi, Those 'O' rings do look very ropey. I understand what you mean about the brass bits now. (actually they're probably phosphor bronze). Also, having had a look at some pics of injectors I can see my memory was playing tricks on me when I said the 'O' rings on each end of the injector are identical. The seal on the "head" end is different (bear in mind if you decide to change "head" end seals you'll need a special tool - you can get them on the internet quite cheaply, or get a specialist to do it). Unless you're worried about the state of those seals you can leave them as they are provided you haven't disturbed them. The injectors are held in place by clamping plates so you would not be likely to have disturbed them unless you've undone the clamps, and even if you did undo the clamps it's likely the seals would be affected providing you haven't physically moved the injectors. The "O" rings in your photographs are identical and these can be obtained from fuel injection specialists. When I removed the inlet manifold some of the brass inserts stayed in the manifold and the rest stayed with their injectors - it looks like your's have done the same. I would replace all 8 with new ones.
 
Hi, Those 'O' rings do look very ropey. I understand what you mean about the brass bits now. (actually they're probably phosphor bronze). Also, having had a look at some pics of injectors I can see my memory was playing tricks on me when I said the 'O' rings on each end of the injector are identical. The seal on the "head" end is different (bear in mind if you decide to change "head" end seals you'll need a special tool - you can get them on the internet quite cheaply, or get a specialist to do it). Unless you're worried about the state of those seals you can leave them as they are provided you haven't disturbed them. The injectors are held in place by clamping plates so you would not be likely to have disturbed them unless you've undone the clamps, and even if you did undo the clamps it's likely the seals would be affected providing you haven't physically moved the injectors. The "O" rings in your photographs are identical and these can be obtained from fuel injection specialists. When I removed the inlet manifold some of the brass inserts stayed in the manifold and the rest stayed with their injectors - it looks like your's have done the same. I would replace all 8 with new ones.
Thanks for the help, the injectors are staying put. I'm just changing manifolds to rid the p1031 error, stuck flaps....cheers
 
Thanks for the help, the injectors are staying put. I'm just changing manifolds to rid the p1031 error, stuck flaps....cheers
I would never do all the job with removing the manifold without sending the injectors to refurbishment at the same time.
 
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I would never då all the job with removing the manifold without sending the injectors to refurbishment at the same time.

And this is exactly what i'm doing today. The inlet manifolds will need to come off when it goes in to have its loom changed next week. Perfect opportunity to change the injectors (which I've had advice may be my issue).
 
I would never do all the job with removing the manifold without sending the injectors to refurbishment at the same time.
I'd be tempted to, but I think it needs extra tools to extract the injectors properly? and potentially more seals etc etc. Not had any issues with this fsi that indicate injectors are faulty, apart from the p1031 fault it actually went really well. although the injectors I removed from the fsi I broke did have alot of carbon build up on the tips which must alter the spray pattern..if I was keeping it long term I'd probably do it but I'm moving onto veg oil burning instead of petrol......cheers
 
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