[lachoradkov]

Great job AlexUK,

I thought too there would be significant difference when I fixed mine, but couldn't feel any... Maybe improvement in the higher rpm and better fuel efficiency.

Would you post the link or part number of the new solenoids?

Thanks

 

[AlexUK]

Vacuum solenoids are p/n 077 906 283. I think later versions came with a letter suffix.

Mine cost ~£20 each ($25) used.

Check the resistance; I read on here they should be <30 Ohms. One of my failed ones was 304 Ohms:

 

[Humphrey]

Vacuum solenoids are p/n 077 906 283. I think later versions came with a letter suffix.

Mine cost ~£20 each ($25) used.

Check the resistance; I read on here they should be <30 Ohms. One of my failed ones was 304 Ohms:

View attachment 257992

service manual says between 55 and 65 Ohms

 

[michael.listek42]

Hello to everyone in the community.

I had issue with my variable intake system. One of the stoppers on the cast part that stop the levers from the spring tension broke. Those cast parts are not sold anywhere, eventually you need new intake manifold for $2k+…

I managed to find the right person who made those for me from billet aluminum. If anybody looks for those part you can message me

Yesss!! Finally I was sent to the correct thread! I am in need of those stoppers and cant seem to find the ones that seem like they're gonna be more durable than those plastic stocked ones they come with. I see you can grab the aluminum ones or you know someone who mills them for the 2004 VW Touareg V8 Double intake manifold engine? If so how much are they?

 

[New2Tregs]

Yesss!! Finally I was sent to the correct thread! I am in need of those stoppers and cant seem to find the ones that seem like they're gonna be more durable than those plastic stocked ones they come with. I see you can grab the aluminum ones or you know someone who mills them for the 2004 VW Touareg V8 Double intake manifold engine? If so how much are they?

I believe the bold print states that. PM them.

I managed to find the right person who made those for me from billet aluminum. If anybody looks for those part you can message me. Price is $250 for both

 

[dapinitial]

Where can I get the billet and arms too? I have pods and I have a new-to-me intake from the junkyard. My pods are ripped arms broken and the mechanism is seized at ~160K — I’m going to rebuild this donor intake after media blasting. I want to upgrade this and my original intake. I plan to sell my original after the rebuild also — unless the new to new me is inferior

 

[lachoradkov]

I can get them for you, $250 for both.
The billet links are available from gruvenparts.

If you are planing to rebuild the intake manifold, watch this video. This guy did it for his audi s4 and shared some useful tips. I like the gold color thermal resisting shield that he installed on the bottom of the manifold at the end of the video.

PM me for the billet parts

PS don’t forget to order the new seals, the inside pair comes from China so it takes a while…

 

[dapinitial]

Cool, we did this on my S4 B7 as well before I felt capable of doing all this alone but reused all parts and made our own deal with black hitemp but I want to replace everything nicely (although nothing was ever wrong with the S4 and the guy who bought it still rocks it 6 years later and keeps on touch!)

This video is pure gold!

 

[bluedoggiant]

Where can I get the billet and arms too? I have pods and I have a new-to-me intake from the junkyard. My pods are ripped arms broken and the mechanism is seized at ~160K — I’m going to rebuild this donor intake after media blasting. I want to upgrade this and my original intake. I plan to sell my original after the rebuild also — unless the new to new me is inferior

I feel guilty for scrapping my old intake manifold when I purchased a new Pierburg unit. But my old unit broke where OP created new parts when a technician was attempting to pull my rods to clean so I thought it was toast. With OPs creation I suspect we will be able to refurbish these manifolds more easily.

 

[dapinitial]

If anyone wants to purchase my old one after I refinish it lmk. I can gold thermal shield and paint it whatever color and provide the silicon tubing for vacuums upgrade the actuator pod arms etc to billet whatever you like… I’m starting on my new one once I get back from holiday. I’m just glass bead media blasting the one I have sitting out and hopefully the throttle body and fuel rail are solid and I get great gas mileage. I was getting 19.5mpg on the way to Mount Hood with Lucas high mileage last winter… but then the problem happened 🤷🏻‍♂️

 

[bluedoggiant]

If anyone wants to purchase my old one after I refinish it lmk. I can gold thermal shield and paint it whatever color and provide the silicon tubing for vacuums upgrade the actuator pod arms etc to billet whatever you like… I’m starting on my new one once I get back from holiday. I’m just glass bead media blasting the one I have sitting out and hopefully the throttle body and fuel rail are solid and I get great gas mileage. I was getting 19.5mpg on the way to Mount Hood with Lucas high mileage last winter… but then the problem happened 🤷🏻‍♂️

I replaced my manifold expecting gains in power curve and MPG. While I did experience an improvement, I was shocked at how little. The single biggest improvement I have made to the performance and drivability of my AXQ, and what I recommend to everyone with a high mileage AXQ, is replacing the primary O2s with fresh Bosch sensors. Massive MPG (something like 5mpg on highway improvement) and drivability improvement, it was fairly shocking and fairly cheap and simple to do.

 

[dapinitial]

Good advice. I’ve considered doing them as well, but one thing at a time. I know my intake
Manifold is seized because the arms are broken and their assembly won’t budge. I’m at ~160K and I off-road so it’s time

 

[bluedoggiant]

Good advice. I’ve considered doing them as well, but one thing at a time. I know my intake
Manifold is seized because the arms are broken and their assembly won’t budge. I’m at ~160K and I off-road so it’s time

I was in your same boat, had mine seized in the resting position and did the o2 sensor replacement a few months later. Best of luck these trucks are awesome.

 

[dapinitial]

Dropping it off tomorrow at the machine shop!

 

[dapinitial]

Update, YOU MUST CLEAN BY HAND BEFORE TAKING TO THE MACHINE SHOP! Lol... I didn't know. I had to get a puller from harbor freight to handle removing the assembly that rotates the plastic flappers.

I am going to be using a couple of fat nylon brushes and loads of carb cleaner in the alley wearing my respirator... but once I am done I'll post pics... probably after holidays... I am planning to restore my original intake manifold and I'll paint and and do whatever, replace with the aluminum arms, silicon hoses, etc. LMK if anyone would like to purchase! I am in Seattle.

 

[dapinitial]

Update. It’s being ultrasonic cleaned now. Will likely media blast next week. What a mess though. The carbon buildup was so fierce on the side where the arm broke. It is actually rock solid and I asked the shop that has the ultrasonic cleaner to get it out of me… I also broke a park using the 3 way puller — when I turned the screw like I did for the left side that came out easily no problemo the right side literally cracked and disintegrated. Bullocks

 

[lachoradkov]

That’s great, keep us updated, I am curious how it will look after the media blast.
I’ll do the same to mine after I clear my garage soon… I have also 3 repair jobs on the queue before that

 

[dapinitial]

I’m going to paint it either bronze, gold, or maybe tennis ball yellow. Whichever I decide to do I’ll also match my calipers.

wrapped the poly bushings for upper control arms with plumbers tape. No squeaks! 50K miles on my pirelli scorpion all terrain plus tires… time for new ones and decided no Ko3 and will get the same set. Ready for snowboarding season and will hopefully finish the intake manifold job before 1/19/2025! Hoping to also find a complimentary silicone tube color for the vacuum whatever I paint the intake manifold and calipers with — decisions!

 

[dapinitial]

I can't say enough good about @lachoradkov <3 Not only did he handle all the incidentals in this post, but when I needed help, he immediately responded. Last night I sent him the funds and already I received a USPS tracking number for IMPROVED aluminum the parts that I needed! I've ordered everything else that is required to finish this up... Hopefully I'll be able to get it done during the beginning of January 2025 when I return from my extended vacation starting next week. I am planning to document this all in another thread since this is a pretty process-involved job but I want to share how I went about it and I'll document costs, actual labor, things that I outsourced (ultrasonic cleaning and media blasting) and my whole process to repaint the intake manifold and bring this Touareg back to life! 136K miles and counting! The problem I experienced was I was giving it hell and it started to not be as responsive off the line anymore. I discovered that there was a broken actuator arm. I replaced it. It broke again. I researched and decided that that internal flappers were frozen, seized due to carbon build up. I sourced another intake manifold so that I don't lose my ski machine for mountains and have begun the process to revive! Stay tuned Clubtouaregfamily!

 

[dapinitial]

All clean! Media blasting next and repainting bronze to match the calipers!! New seals and @lachoradkov ’s parts and aluminum arms coming this weekend. Hoping to finish this up by 1/19/2025– leaving till new years!! Ordered all new hex nuts, solenoids, and gaskets and seals and Orings and now just looking for how much vacuum tube and diameter in silicon to refresh the whole engine