Long day working on the car today. For a while now I've known that my car had picked up the common intake manifold problem, which brings up the fault code: P2015-Intake Manifold Flap Position Sensor (Bank 1): Implausible Signal. I also had the check engine light come on recently in relation to this and so decided to press on with replacing the intake manifold as soon as possible. If you want any more info about this fault I highly recommend checking out this video:
https://youtu.be/yvfVUkuPY0k. VW have brought out an updated version of the intake manifold which is part no. 06J-133-201-BH and hopefully addresses most of these issues, and this is the part that I fitted. I decided while I had the manifold off and seeing as my car has just passed 100,000 miles that it would benefit from a cleaning of the intake valves too.
So this is how we started. I have already removed the engine cover, airbag and oil filter for access. I followed this particular video as a guide:
https://youtu.be/c7c35MJq5e0 and found it very useful.
Found some parts of the removal pretty tricky. There is a support bracket the connects the throttle body to the engine block which access to is terrible. Also removing the intake hose from the throttle body itself took me a while but some very careful prying with a few picks finally had it off:
Took me a couple of hours to get to this point but finally the manifold was off!
It's common to have a couple of injectors get stuck in the manifold and come out with it. I got lucky and had all four injectors come out!
On with the decarbon! It was definitely needed as you can see:
I found it difficult to photo the results but it's much better now! Hopefully you can tell from these awful pics:
Few bits need swapping from old to new manifold such as throttle body and fuel rail etc:
Injectors needed a little clean too:
When the injectors come out during this removal, the seals must be replaced. There's a special VW tool for this seal replacement but I used a Sealey equivalent. Luckily I was able to get 4 new seal kits before starting the job.
These vanes were pretty disgusting but came up pretty well after being cleaned:
Freshly cleaned injectors with new seals fitted back to the head:
Installation went pretty smoothly thankfully. Lots and lots of double checking that I'd connected everything back up later and she fired into life second time of asking (fuel system needed time to prime).
Was going to change the fuel filter today too but I didn't fancy any more time out in the rain than necessary