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Old 04-10-2010   #1
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DIY: V10 TDI Intake Removal and cleaning

OK Ive spent quite a while digging through old posts and stickys and I cant find what Im looking for.

I decided to tackle the intake cleaning job meself and its pretty tough on the 2004.

I can get to all the bolts now except the back ones and was wondering if someone has had experience removing the fuel filter - heater - pump assembly betwixt the intake manifolds?

any input is appreciated,
Justin

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Old 04-10-2010   #2
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Well I figured out how to get the filter assy out. it just pops in to some mounting studs in the back with rubber sockets... there is a connector tho, I assume it is the FFS (flex fuel sensor)... am I right? why is it on a diesel? oh, and I correct my last post by saying there is no pump in that assembly... looks like the delivery pumps are driven by the back of each cam.

I would do a write up on this if enough folks are intersted... i took some pics along the way and plan to post them.

if there's already a sticky about taking off the intake manifolds on the v10, I couldnt find it... could someone point me to it if there is?

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Old 04-10-2010   #3
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I don't remember seeing a sticky, sure would be nice to see a photo step by step.
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Old 04-11-2010   #4
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I would love to see a write up on this.
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Old 04-11-2010   #5
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I'm planning on digging around in there pretty soon myself. Wouldn't mind reading about it first instead of blundering thru it like I usually do One thing I've noticed of interest is the plastic engine covers are different on the '04's than the later years. Might be that the airboxes etc are unique too
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Old 04-12-2010   #6
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not sure of the differences in other years, some could be major.
according to the dealer, they allow FOUR hours for their tech's to do this!!! that doesnt include the hot-tanking. Ive seen on youtube where guys have burned out the soot on their four bangers...with a turbo torch and airgun... i just dont like that idea at all. theres already enough that could go wrong while doing this on a V10, why risk warping a manifold?
It took me about 4 hours to take them off, I was extra careful, and still messed up a coolant hose.

Ill post pics this week...
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Old 04-12-2010   #7
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Quote:
Originally Posted by haywood801 View Post
not sure of the differences in other years, some could be major.
according to the dealer, they allow FOUR hours for their tech's to do this!!! that doesnt include the hot-tanking. Ive seen on youtube where guys have burned out the soot on their four bangers...with a turbo torch and airgun... i just dont like that idea at all. theres already enough that could go wrong while doing this on a V10, why risk warping a manifold?
It took me about 4 hours to take them off, I was extra careful, and still messed up a coolant hose.

Ill post pics this week...
I'm definately interested in seeing your write-up and pics! Thanks!
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Old 04-25-2010   #8
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this project is complete and I have some decent pics of the process.

Im goin to do a write up of it, what is the best way to post a write up?

some people here are attaching a pdf, and some are pasting pics into the text.

what does our administrator prefer?
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2004 TDI V10
1997 Ford F350 Crewcab 24V P-pump cummins 4x4 longbed with Gearvenders Overdrive 6th gear.
Minus one 49 Hudson Saltflats car (with visitation rights)
Minus one Dodge Cummins
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Old 04-26-2010   #9
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Whatever works best for you...pdf is nice since people can print it out, pictures are also nice since they are visual. Personally I'd rather a pdf I can print out and have with me while I do the work.
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Old 05-03-2010   #10
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Writeup for intake removal and cleaning

V10 Intake Removal.pdf

see attachment.
I hope this helps some folks out.

Justin

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1997 Ford F350 Crewcab 24V P-pump cummins 4x4 longbed with Gearvenders Overdrive 6th gear.
Minus one 49 Hudson Saltflats car (with visitation rights)
Minus one Dodge Cummins
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