Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner Delete Repair Kit Plate Blanks

Transcription

1 Audi VW 2.0 TFSI T FSI Inlet Intake Manifold Swirl Flap Runner Delete Repair Kit Plate Blanks Introduction Runner flaps fitted within the inlet manifold on Audi and VW 2.0 TFSI vehicles restrict airflow limiting performance. Our kit allows you to completely remove this system, vastly improving airflow; allowing better tuning and preventing failure of the runner flap components. The Problem The runner flaps within the inlet manifold limit airflow and performance. The factory fitted inlet manifolds on EA113 engines have runner flaps fitted

2 within. Much like throttle body flaps these open and close to adjust airflow. These ultimately restrict airflow, even when fully open airflow is restricted. This becomes an issue the more the vehicle is tuned. Carbon can also build up on these moving parts providing more restriction and can in some cases causes failure of the moving parts within the manifold. Symptoms of the fault If the runner flaps are operating correctly there will likely be no symptoms of a fault. The benefits will only be realised when the runners are removed; improving airflow. If the runners are faulty or carbon build ups have formed this can affect vehicle performance. Vehicles affected and compatibility 2.0T FSI EA113 engines: Audi TT MK (From 57 plate) 2.0T FSI Audi TTS MK T FSI Audi A3 MK T FSI Audi A4 B (From 55 plate) 2.0T FSI (FWD) Audi A4 B (From 55 plate) 2.0T FSI (Quattro) VW Passat B T FSI VW Jetta MK (From 55 plate) 2.0T FSI VW Golf/GTI MK T FSI VW R Models MK6 R T FSI Our solution Remove the runner flaps using our kit to improve airflow in the inlet manifold. Remove the runner flaps completely from the manifold using our kit. Our precision engineered CNC billet aluminium parts allow you to remove the runner flaps. Our parts replace the runner bearing blocks and the crank arm; sealing the

3 manifold and vastly improving airflow. Ideal for stock vehicles to improve airflow and prevent carbon build up- even better for tuned engines. Customers with tuned engines have noted quicker throttle response, less turbo lag, improved torque and BHP gains when deleting the runner flaps. You will receive X4 Left hand bearing block blanks X4 Right hand bearing block blanks 1X Crank arm blank 1X Manifold gasket X8R Ltd Step 1: Remove Ball Joint Crank Arm

4 Locate the ball joint crank arm on the end of the manifold. Using a small flat bladed screwdriver lever the retaining clip out of position and save for reinstall. Using a pair of grips pull the ball joint crank arm out of the manifold. Please note the seal on the crank arm in the images. If this comes out with the crank arm please remove and reinsert in to the manifold, this is important to achieve a seal when blanking off. Step 2: Insert Our Crank Arm Blank

5 Insert our blank in to the hole left by the crank arm. Refit retaining clip (check image for orientation) this will secure the blank in position. Step 3: Remove the Runner Flaps and Clean Manifold Using a pair of grips, grip the runner flaps and pull away from the manifold. Pull

6 each flap gently until the complete assembly can be pulled loose from the manifold. At this point it is a good idea to clean any carbon deposits from the manifold. Particularly where the gasket sits and where the bearing block blanks locate. Step 4: Insert Our Bearing Block Blanks Insert our blanks in place of the bearing blocks from the runner flaps. These simply push in to position. The blanks are handed left and right, insert 4x left hand and 4x right hand blanks. Press the blanks firmly in to position to sit flush with the manifold, if they do not fully engage clean any carbon deposits and push back in to position.

7 Step 5: Fit Our Replacement Manifold Gasket Again ensuring the manifold is clean and free of deposits; insert our new gasket in to the groove on the manifold. This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2018.

8 Audi VW Seat Skoda 2.0 TFSI PCV Valve Delete Removal Plate Instructions Introduction, A diaphragm splits or deteriorates within the PCV unit causing vehicle faults. Symptoms of fault

9 Poor MPG, rough idle, boost loss, check engine light, sluggish performance, significant power losses, poor drivability. Oil leaking from oil cap, oil in the engine bay, PCV pipe work leaking, boost / vac leaks. The cause A diaphragm splits or deteriorates within the PCV unit causing vehicle faults. One of the most common faults on the 2.0 TFSI engine is the failure of the pressure control valve (PCV). This valve is designed to recirculate crankcase gases into the intake manifold. Within the valve is a soft diaphragm which is prone to splitting over time, this can occur on stock engines but is very common on tuned engines. This results in excessive blow by entering the inlet manifold at idle causing oil leaks in the engine bay from crankcase pressure, rough idle, fuel economy decline and boost loss. With boost pressure below where it should be you will notice significant power losses and poor throttle response. Check our symptoms section to see common symptoms of the failure of this valve. The solution Install our PCV delete unit and restore performance to your vehicle, removing the poor-quality component that commonly fails. Our replacement unit installs very easily and quickly. Upon fitting you will notice a vast improvement in performance and power if your OEM PCV has failed. Our beautifully machined billet anodised aluminium unit (check our feedback for the quality of our manufacturing). Directly replaces the PCV unit deleting the OEM PCV system. Removing the original flawed design part from the engine. Our unit links the two internal ports together, this emulates what happens inside the OEM PCV when the engine is on boost, but removes the fragile components which commonly fail. Our unit converts the system to a vacuum only based system. PCV function is properly retained and no emissions functions are effected with our unit. Our kit also includes a blank for the inlet manifold. This is engineered with three ports, where either our vacuum nipples can be fitted (included in kit) to run a boost gauge or water spray controller or these can be blanked off (blanks included). Install our kit and restore full performance to your vehicle, engineered to last the life of the vehicle. What you will receive

10 Billet Black Anodised Aluminium Valve Cover Plate Billet Silver Anodised Aluminium PCV Adapter Billet Silver Anodised Aluminium Manifold Cap High quality Viton O-Rings To Provide Seal Between Components Retaining Clip Vacuum Nipples X3 Blanking Screws X3 (for use in place of vacuum nipples) Vehicles affected Compatible with timing belt-driven 2.0 TFSI engines. Audi A1 2.0 TFSI, CDLH engines to Audi A3 (8P) 2.0 TFSI, AXX, BPY, BWA, CCZA, CDLA, BHZ, engines Audi S3 (8P) 2.0 TFSI BHZ, CDLA engines Audi A4 B7 2.0 TFSI Audi TT 2.0 TFSI & 2.0 TTS BWA, AXX, BPY, CDLA, CDLC, engines to Seat Leon Copa 2.0 TFSI 2008 onwards. Seat Leon 2.0 TFSI CCZB, CAWB engines onwards. VW 2.0 litre TFSI engines. Belt cam EA113 engine: VW Golf Mk5 GTI 200bhp VW Golf Mk5 Edition VW Golf Mk6 Edition 35. VW Golf Mk6 Golf R. VW Scirocco Mk3 R 2.0 FSI EA onwards. VW Passat B6 2.0 TFSI AXX, BWA engines Skoda Octavia MK2 2.0 TFSI VRS. BWA engine Information is for guidance only, it is worthwhile checking the intake manifold to

11 ensure your vehicle has a PCV valve as illustrated in the listing. Associated part numbers: 06F129101N, 06F129101C, 06F129101E, 06F129101F, 06F129101K, 06F129101L, 06F129101R, If unsure call or and we can look up your vehicle. Available from X8R Ltd Step 1: Remove PCV Pipe From PCV Unit Push in the knurled tabs each side of the pipe connector and pull the pipe loose from the PCV unit. Make sure to only pull on the pipe connector, the pipe might be brittle and putting pressure on that can cause it to crack. Step 2: Remove PCV Pipe From the Intake Manifold

12 Remove the other end of the PCV pipe. Push in the knurled tabs each side of the pipe connector and pull the pipe loose from the intake manifold. Again make sure to only pull on the pipe connector, the pipe might be brittle and putting pressure on that can cause it to crack. Step 3: Remove Lower Pipe From PCV Unit

13 Repeat as before and remove the lower pipe from the PCV unit. Step 4: Remove the PCV Unit From the Valve Cover

14 Using a T25 screwdriver remove the 4 screws from the PCV unit and remove the PCV unit. Step 5: Fit Our PCV Delete Plate Fit our PCV delete plate, mount using the 4 screws removed in the previous step. Screw the pipe adapter on to the delete plate and tighten with a spanner. This part seals on an O-ring so should not be over tightened.

15 Step 6: Connect Lower Pipe to the Delete Plate Adaptor

16 Push fit the lower pipe connector to the delete plate adapter. Step 7: Fit Our Intake Manifold Cap

17 Push our intake manifold cap on to the intake manifold as shown. Push until fully engaged on the manifold and insert the clip to retain. On the blank is three threads, included in the kit is three vacuum nipples and three blanking screws. You can decide which to fit depending on if you want to run any gauges. We recommend using thread lock or sealant on the nipple threads or blanking screws. This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on or us at Please also check out our instruction guide on YouTube. Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2017