[nikoloz]

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

 

[nikoloz]

broken actuator flap and manifold apart

the inside of an air intake

 

[nikoloz]

assembly

putting it back together after cleaning and make sure you tighten all the bolts to specific torque specs as its critical

 

[nikoloz]

assembly

clean throttle body

 

[nikoloz]

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

 

[nikoloz]

finally you need to do the throttle body alignment with VCDS

 

[nikoloz]

So far this is my cars personal record After repairs its nice to see that you've done something that worked

 

[sydneytreg]

Nice work.
Good diagnosis and as always you have given other a flying start by following you photo guides.

 

[nikoloz]

thank you, hope this will help someone some day

 

[hedditch]

Nice work. Makes a really good "Howto".

Stuart..

 

[unitpump2013]

Good job! It is very helpful to us!

 

[Daniel308d]

thanks heaps for all the photos I had the same problem with the little vacuum plastic arm breaking, I went to the local bearing supplier and we made up a little steel arm the clips on both sides $15 for the two, Is your fuel consumption around town or open Road??

 

[nikoloz]

Thank you, Yes this is city and highway combined, It was early morning so it was easy to maintain constant speed, but mostly im now getting around 17-18 liters per 100 kilometers

 

[Whirly]

What's the throttle body alignment Involve? Pictures would help please. Also what tool did you use for the sensor. Good job bro.

 

[nikoloz]

hi, here is the video demonstrating the Throttle body alignment procedure using ross tech vag com the best tool for all VAG cars,

and for the MAF sensors you need special tool that is star shaped and it has hole in the middle, its not torx tool it is STAR shaped. something like this
5 Point Torx Star Tamper Proof Security Bit Socket Set | eBay

 

[FSJ Guy]

They are commonly called security Torx bits in the USA.

 

[megkrisstore]

What did you use to replace the vacuum lines?

 

[nikoloz]

What did you use to replace the vacuum lines?

any rubber/silicon hose will work if its good quality and same diameter

 

[megkrisstore]

Thanks, but I was told by the auto shop that a regular rubber vacuum hose wouldn't work because the vacuum suction is so great that the rubber hose would collapse. It has to be hard plastic like the one that's presently in there. And they are so expensive from the dealer....

 

[Odessa]

Ya cmotrel cechas ..... moladets )))))