I Found this

[HAWKS]

Morning all.
Help required with this.
I have had a problem with my leak off pipe on the 1st injector(right side) keeps popping off.I decided to replace the pipe from the injector to the fuel pump.The pipe is crushed under the fuel pump.I know its had a new pump fitted in the past.http://i1299.photobucket.com/albums/ag63/ghawks100/th_G053.jpg (http://s1299.photobucket.com/user/ghawks100/media/G053.jpg.html) http://i1299.photobucket.com/albums/ag63/ghawks100/th_G055.jpg (http://s1299.photobucket.com/user/ghawks100/media/G055.jpg.html) I take it it should run over the top of the pump.I will fit a new pipe from pump top injector a cut the old pipe out.
As it was a mess down that side of the engine i thought i would clean the area. I removed the intercooler rubber pipe for cleaning an found this http://i1299.photobucket.com/albums/ag63/ghawks100/th_G049.jpg (http://s1299.photobucket.com/user/ghawks100/media/G049.jpg.html) in here http://i1299.photobucket.com/albums/ag63/ghawks100/th_G048.jpg (http://s1299.photobucket.com/user/ghawks100/media/G048.jpg.html) an here http://i1299.photobucket.com/albums/ag63/ghawks100/th_G047.jpg (http://s1299.photobucket.com/user/ghawks100/media/G047.jpg.html).
Ive cleaned them out now but how big a job is it to remove the inlet manifolds to clean them too http://i1299.photobucket.com/albums/ag63/ghawks100/th_G052.jpg (http://s1299.photobucket.com/user/ghawks100/media/G052.jpg.html).
The car has done 156000 miles an has been well looked after.It drives well no problems at all.
BUT what can cause this to happen.??
Will anything else require cleaning out??
Any help would be appreciated.
Thanks
Graham.

[HAWKS]

Can anyone help with cause of this please.
Also the butter fly flap thing on the side of the inlet manifold that has a vacum pipe on it,i put a new pipe on it an tried to suck it closed.it didnt completely close,it only turned a little way.
Whats it for and how does it work.

[frankc]

All the crud is from your EGR valve feeding sooty exhaust gasses back into your inlet manifold.

Removal of the left and right manifolds from the head involves removing the solid injector pipes to gain access and undoing 7 bolts from the manifold. Apparently the turbo heat shield will also require removal

I believe the manifold flap is to allow a smooth shut down of the engine when turning off (standing by to be corrected), if its not moving properly then I would assume it still has some of that gunk clogging it up.

Hope this helps, frank.

[HAWKS]

Thanks Frank.
So after de-gunking the inlet manifolds,the EGR valve would be the next thing to take out an clean.
What about the intercooler.?? When i removed the rubber pipe from the manifold it was clean.
A job for next week-end.
Graham.

[frankc]

The intercoolers should be a lot cleaner as I believe the EGR feeds into the manifold, and thus after the intercoolers (yours is 2.5 V6 isn't it so should have two).

It's not uncommon to have a small amount of oil in the intercooler, so it makes sense to rinse them out with some petrol or the likes while you have them off.

The EGR will also be clogged so again, makes sense to clean up. Some folk blank them off or have them mapped out but then you risk issues with EML warnings and the engine taking longer to get up to heat, especially in the cold months. Up-side is you no longer run all the sooty exhaust gasses through your engine.

Frank

[HAWKS]

Cheers for advice frank.
I will take out the EGR an clean/replace if needed.
A job for the week end.
The motor runs well.hard to beleive its so gunked up like it was.
I will update after.

[PaulF2.5TDi]

I did my one of my cars inlets last year and they looked similar!

Its not too bad a job - just make sure you have all the gaskets first.
The system is all held on with allen bolts, and I didn't need to remove any glow plugs or injectors on my A4 AFB engine.

I cleaned the manifolds as best as I could, then poured in some kerosene and set light to it to clear it out.

Blanking off the EGR at the same time will help stop it happening in the future.

[HAWKS]

Cheers Paul.
Will i have to get audi gaskets(set/single) or GSF.
I need to take off injector pipes.
Will bleeding them be a pain.??crack them all off or 1 at a time.??
I dont want to go down the route of blanking EGR off.I will clean or replace it.

[PaulF2.5TDi]

I would think GSF is fine - although I got mine from Audi as singles, and they were not expensive.

If you have to take the injector pipes off, stick tape with numbers on them and note where they go on the pump. (Maybe I did too - I may have forgotten)

As for bleeding, I didn't have any problems last time I took all mine off - although some guys have had grief!

If you use a syringe to suck fuel through the injector return pipes first, then crack them all, turn the engine over for a few seconds then do them up at try to start it you should be fine.

[frankc]

Think the big bleeding problems (or maybe bleeding big problems?!!) come when you get air into the VP44, say doing the fuel filter for instance. Taking the high pressure injector pipes off will mean it'll take a few cranks to get fuel back to the injectors, but at least the fuel supply to the pump is good.

I have an injector to replace this weekend so fingers crossed the theory works! Though reading around it seems ok.

Frank

[HAWKS]

Job done..
I removed the manifolds from the block for cleaning.The right side was quite restricted with gunk.The left side wasnt so bad.The EGR valve was only slightly sooty.
I didnt need to remove the injector pipes completely.I only removed them from the injectors and pulled them up out of the way.The manifolds can then be twisted to the side an removed.Bleeding the injectors was easy.I slackened of the first pipe on each side an cranked it over a few times.Tightened them up,an fired up the quattro..
It took about 2hrs to remove an refit.cleaning took ages.
I lost one socket an found a 10mm socket and an allen key.fair swap...
As must is a socket allen key for this job.

[HAWKS]

Audi Part Numbers
Part No for EGR Valve gasket A046 131 547 x2 £3.11 ea
Part No for EGR pipe to inlet pipe A059 131 797 A x1 £1.48 ea
£9.24 Total
Manifold Gaskets x2 not bought from Audi.