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- Jun 2, 2003
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1996 Audi A4 quattro
2.8 V6
12 valves
Did this last weekend, while on vacation. All in all a four hour job.
The EGR temperature sensor sits at the bottom of the IM at the end of a maybe 4" long passage. The passage gets over time more and more narrow due to carbon deposits, and the sensor gets fouled.
First of all, the intake silencer has to be removed. You are looking at the part that attaches to the throttle body. To the left and right you can see two protruding connectors. That's where the valve cover breather hoses go. In the double-bottom you can see the PCV valve, which is just a silicone flap valve. Under the driver side valve cover breather hose barb you can see another smaller protrusion (My shoes is pointing right at it). A small vacuum hose gets connected there. It sucks blow-by solids into the throttle body, right behind the butterfly valves. I hadn't pulled off the intake silencer in 25 or 30k miles, and I did not clean it before I took the picture. There was almost no oily residue.
The intake manifold has been removed. It's been 60k miles since I pulled the IM out. There is some oil and grit. The oil is from the always "weeping" valley cover pan gasket (see ovoid lid between heads) and from the head gaskets, which have been "weeping" for at least the last 100k miles. The "weeping" has not gotten worse since I last had the IM out. The duct tape was put there for the obvious reason. ;-)
The valley pan removed. The green gasket is the old polyperse wax paper gasket.
In order to minimize and hopefully stop all leakage, I lapped the VP cover to make sure it was 100% flat. The process isn't done in the picture. You can see the low spots appear a bit darker on the flange.
With the IM off, let's take a look at a valve. That's the best view I could get on the fly.
I removed the fuel rail from the IM and pulled the injectors. I replaced all 12 O-rings and reinstalled the injectors and fuel rail.
1996 Audi A4 quattro
2.8 V6
12 valves
Did this last weekend, while on vacation. All in all a four hour job.
The EGR temperature sensor sits at the bottom of the IM at the end of a maybe 4" long passage. The passage gets over time more and more narrow due to carbon deposits, and the sensor gets fouled.
First of all, the intake silencer has to be removed. You are looking at the part that attaches to the throttle body. To the left and right you can see two protruding connectors. That's where the valve cover breather hoses go. In the double-bottom you can see the PCV valve, which is just a silicone flap valve. Under the driver side valve cover breather hose barb you can see another smaller protrusion (My shoes is pointing right at it). A small vacuum hose gets connected there. It sucks blow-by solids into the throttle body, right behind the butterfly valves. I hadn't pulled off the intake silencer in 25 or 30k miles, and I did not clean it before I took the picture. There was almost no oily residue.
The intake manifold has been removed. It's been 60k miles since I pulled the IM out. There is some oil and grit. The oil is from the always "weeping" valley cover pan gasket (see ovoid lid between heads) and from the head gaskets, which have been "weeping" for at least the last 100k miles. The "weeping" has not gotten worse since I last had the IM out. The duct tape was put there for the obvious reason. ;-)
The valley pan removed. The green gasket is the old polyperse wax paper gasket.
In order to minimize and hopefully stop all leakage, I lapped the VP cover to make sure it was 100% flat. The process isn't done in the picture. You can see the low spots appear a bit darker on the flange.
With the IM off, let's take a look at a valve. That's the best view I could get on the fly.
I removed the fuel rail from the IM and pulled the injectors. I replaced all 12 O-rings and reinstalled the injectors and fuel rail.