Manifold cleaning & common rail fuel system - help needed

[TheMatador]

Hi - is there anyone in the Bracknell/Reading/Camberley area with experience on Common Rail fuel system who fancies helping out with a strip-down and clean of the intake manifolds on my 3.0tdi? Happy to return the favour

Or can anyone recommend a good mechanic in the same area with a reasonable day rate?

Looks like the job will involve dismantling some of the high pressure common rail fuel system over the top of the engine so I'd really like someone with some experience with me!

[kite]

I have no previous with the high pressure but am willing to help
undo a few nuts.......

[TheMatador]

Thanks Kite - much appreciated. I've got the workshop manuals so I can start to work out what's involved and what we might be getting into. Looks like the fuel system will self purge as long as the HP pump is primed...

[kite]

don't know when you plan on doing the work but I'm away for the next couple of weeks.
Also I work shifts so if you plan for work on the weekend give me a bit of notice please....

[cameron1]

enjoying the community spirit, keep up the good work

[v6quattrogrip]

You don't need to undo hp lines it's only 2 lines over the top and they are not hp when the engine is off. A couple of bugger bolts to get to you will need a long Allen key aswell. On the left bank as you look at it the top right bolt will stay in as you lift it off and a tab on the right bank will need bending back it's on the left side second bolt up iirc. If your doing this i would also say to the actuator arms aswell they are only £8 each from audi. As to cleaning i used a bucket of diesel and let them soak and then scrapped off the crud.

Sent from my E6553 using Tapatalk

[PaulF2.5TDi]

If you are going to take off the manifolds, get the swirl flap bearing and flap kit as a minimum from Airshox, a site sponsor (i believe??) as the swirl flaps are a known problem with this engine.

AirShox Brochure_EN.pdf - Google Drive

Cleaning is a bit of an ****, but can be done.
Of course Airshox do a complete manifold option too if you don't want the hassle……...

There are some rubber gaskets IIRC on the top and bottom manifolds to replace, but a soak in near boiling water can rejuvenate them if you don't get all of them

I don't recall anything too difficult - a little patience was all it took.

I also recall the bracket needing a small amount of bendage