T1 V8 intake manifold repair, vacuum hose repair, cleaning MAF - Club Touareg Forums
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post #1 of 16 Old 04-30-2016 Thread Starter
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T1 V8 intake manifold repair, vacuum hose repair, cleaning MAF. DIY

hi touareg lovers, finally had time to do some repairs. some things to share if someone will have same problem, ill be glad to help.
few month now fuel consumption was really beyond any acceptable numbers but weirdly CEL only came up once, so i hooked my VCDS and scanned, i got P0171 and P0174, so both banks were too lean, i carried on testing to narrow down and make sure it was vacuum problem and not something else, i found few vacuum hoses split open so i changed all of them
then i decided to take care of intake actuators, as most of you know touaregs have very clever variable 3 staged intake system,
in my case top actuator flap was stuck and the bottom one was hardly moving, so i took it apart, sadly i discovered that top one was broken, i dont know how or why but the rest of the plastic was also very brittle and it fell apart while i was trying to take it off, so now i had to take whole intake off and change the top variable flap completely, got the used part really cheap so not to worry, i took me 2 days to take everything off give it deep clean, swap the parts, reassemble the manifold and put it back on and start it up, i also cleaned the throttle body and MAF sensors if any member will need any detailed info about anything involved im happy to help, ill put lot of photos so they speak for themselves Click image for larger version

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post #2 of 16 Old 04-30-2016 Thread Starter
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broken actuator flap and manifold apart

the inside of an air intake
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post #3 of 16 Old 04-30-2016 Thread Starter
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assembly

putting it back together after cleaning and make sure you tighten all the bolts to specific torque specs as its critical
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post #4 of 16 Old 04-30-2016 Thread Starter
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assembly

clean throttle body
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post #5 of 16 Old 04-30-2016 Thread Starter
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cleaning MAF

you need to use special tool to remove the IAT/MAF sensor, and make sure you wait until its 100% dry before putting it back
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post #6 of 16 Old 04-30-2016 Thread Starter
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finally you need to do the throttle body alignment with VCDS
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post #7 of 16 Old 05-04-2016 Thread Starter
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So far this is my cars personal record After repairs its nice to see that you've done something that worked
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post #8 of 16 Old 05-04-2016
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Nice work.
Good diagnosis and as always you have given other a flying start by following you photo guides.
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post #9 of 16 Old 05-04-2016 Thread Starter
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thank you, hope this will help someone some day
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post #10 of 16 Old 05-04-2016
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Nice work. Makes a really good "Howto".

Stuart..

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ACC, Front & Side Assist, Paddle Shift, Towbar & Trailer Module, Fiscon Bluetooth. Reversing Camera, Front Fog Lamps, Redarc TowPro Brake Controller, T1 Door Warning Lamps, T1 Under Seat Drawer, Alloy Skid Plate, 5ton Winch, Cayenne Front and Rear Sway Bars, Tuned by Oettinger, Retrofitted 6 Piston Brembo Front Brake Callipers, Sports Steering Wheel, TPMS (OEM), Dual Batteries
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