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

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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.

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

Locate the ball joint crank arm on the end of the manifold.

Please note the seal on the crank arm in the images.

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

each flap gently until the complete assembly can be pulled loose from the

At this point it is a good idea to clean any carbon deposits from the

Step 4: Insert Our Bearing Block Blanks Insert our blanks in place of the

The blanks are handed left and right, insert 4x left hand and 4x right hand

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.

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.

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

ensure your vehicle has a PCV valve as illustrated in the listing.

06F129101R, If unsure call or E-Mail and we can look up your vehicle. Available from X8R Ltd www.

uk Step 1: Remove PCV Pipe From PCV Unit Push in the knurled tabs each side of the pipe

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

18 Mercedes Benz V6 M272 and V8 M273 Intake Inlet Manifold Air Flap Runner Lever Repair Instructions Introduction The Problem A plastic lever on the intake manifold snaps which leads to malfunction of the tumble / swirl flaps and causes vehicle faults.

19 Mercedes-Benz vehicles with the V6 M272 and V8 M273 engines commonly suffer from failure of the intake manifold. These manifolds are fitted with tumble / swirl flaps. The purpose of these is to increase air speed / tumble at low RPM which creates better torque for the motor at low RPM, enhanced fuel economy and reduces emissions. Unfortunately, the design of this mechanism is flawed and commonly fails. Previously necessitating replacement of the complete intake manifold at vast expense. In reality it is only a small part of the manifold that fails due to poor quality construction. On the intake manifold below the secondary air injection pump sits a plastic lever- integral to the manifolds function. As carbon builds up in the inside of the manifold over time this puts more pressure on the air doors / swirl flaps which connect to the lever, this inevitably cracks the plastic lever which is the inferior quality component. This leads to the lever no longer moving the air doors / swirl flaps inside the manifold runners. This is what causes the symptoms noted. Symptoms of the fault Symptoms can include some or all of the below: Check engine light (CEL) is lit / on with P code P2004, P2005 or P2006 stored in the system. Engine control module has stored pending codes for intake manifold, air flap or runner control system. Error messages; tumble flap stuck in activated position, intake manifold runner control stuck closed. Emissions test failure. Poor idle, loss of power, delayed acceleration, increased fuel consumption. To diagnose this fault; you can visually inspect the manifold, remove engine covers and inspect intake manifold from above, using a torch you should be able to see down the front of the manifold and see if the lever is damaged. Vehicles affected and compatibility This information should be used for guidance only, please inspect the intake manifold to ensure the lever is the fault:

20 Mercedes C , 2007 Mercedes C 230 4MATIC Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 230 RWD Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 230 Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes C 250 4MATIC Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 250 RWD Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 250 Sedan 2008, 2009, 2010, 2011 Mercedes C 280 4MATIC Sedan 2006, 2007, 2008, 2009, 2010, 2011, 2012 Mercedes C 280 RWD Sedan 2006, 2007, 2008, 2009, 2010, 2011, 2012 Mercedes C 280 Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes C 300 4MATIC Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 300 RWD Sedan 2008, 2009, 2010, 2011, 2012 Mercedes C 300 Sedan 2008, 2009, 2010, 2011 Mercedes C 350 4MATIC Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes C 350 RWD Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes C 350 Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes CLC Mercedes CLK 350 Convertible 2006, 2007, 2008, 2009 Mercedes CLK 350 Coupe 2006, 2007, 2008, 2009 Mercedes E 280 4MATIC Sedan 2007, 2008, 2009 Mercedes E 280 RWD Sedan 2007, 2008, 2009 Mercedes E 350 4MATIC Sedan 2006, 2007, 2008, 2009, 2010, 2011

21 Mercedes E 350 4MATIC Wagon 2005, 2006, 2007, 2008, 2009, 2011 Mercedes E 350 Convertible 2011 Mercedes E 350 Coupe 2010, 2011 Mercedes E 350 RWD Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes E 350 RWD Wagon 2005, 2006, 2007, 2008, 2009, 2011 Mercedes E 350 Sedan 2006, 2007, 2008, 2009, 2010, 2011 Mercedes E 350 Wagon 2006 Mercedes GL Mercedes GLK , 2010, 2011, 2012 Mercedes GLK 350 4MATIC 2009, 2010, 2011, 2012 Mercedes GLK 350 RWD 2009, 2010, 2011, 2012 Mercedes ML , 2011 Mercedes ML , 2010, 2011 Mercedes ML 350 4MATIC 2005, 2006, 2007, 2008, 2009, 2010, 2011 Mercedes ML 350 RWD 2005, 2006, 2007, 2008, 2009, 2010, 2011 Mercedes ML 450 HYBRID 4MATIC 2010, 2011 Mercedes ML 450 HYBRID RWD 2010, 2011 Mercedes R , 2006, 2007, 2008, 2009, 2010, 2011 Mercedes R , 2006, 2007, 2008, 2009, 2010, 2011 Mercedes R , 2006, 2007, 2008, 2009, 2010, 2011 Mercedes R 350 4MATIC 2005, 2006, 2007, 2008, 2009, 2010, 2011 Mercedes R 350 RWD 2005, 2006, 2007, 2008, 2009, 2010, 2011

22 Mercedes S 400 HYBRID Sedan 2010, 2011, 2012 Mercedes SLK 280 Convertible 2006, 2007, 2008, 2009, 2010, 2011 Mercedes SLK 300 Convertible 2006, 2007, 2008, 2009, 2010, 2011 Mercedes SLK 350 Convertible 2005, 2006, 2007, 2008 Mercedes-Benz V6 M272 and V8 M273 engines only. Associated part numbers: , , , , , , , , , , , , , A , A , A , A , A , A , A , A Our solution Install our metal replacement lever and restore full function to the intake manifold, avoid the cost of a complete new manifold. An improved design part which won t fail. Mercedes-Benz solution to this common fault is to replace the complete intake manifold, not only is this extremely expensive but also a replacement manifold will have the same plastic lever which would just fail again. Our solution allows you to replace just the lever that fails. Our replacement lever is precision machined from high quality billet aluminium, meaning it will never fail like the OEM part. We provide this at a massive saving compared to a complete new manifold which would just fail again. Our part is perfectly machined to fit in the same way as the OEM part and takes moments to exchange once the manifold is removed. Our part will restore full function to the mechanism, check out our videos and instructions. We also include a repair for the vacuum actuator arm in case the original has snapped or the ball joint has worn. You will receive 1x Billet aluminium CNC machined lever 2x Linkage arms

23 1x Actuator arm repair+ Step 1: Remove lever arms and actuator arm ball joint Using a pry tool or flat bladed screw driver gently pry the arms and the actuator ball loose from the lever. Step 2: Remove lever bolt and remove lever

24 Using a T30 Torx screwdriver remove the bolt retaining the lever. Remove the lever and operating arms. Step 3: Grease the ball joints on the new lever and arms

25 Apply a light covering of grease to all ball joints / ball joint receivers on the lever and linkage arms. Do not apply too much grease as this will inhibit fitting. Step 4: Mount the new lever

27 Mount the new lever and refasten the bolt. Apply thread lock compound to the bolt thread and torque up to 9nm / 80in lbs. Step 5: Press fit linkage arms and actuator arm. Press the linkage arms in to the plastic receivers using a pair of pliers. Press the actuator arm on to the ball joint on the lever.

28 Step 6: Actuator arm repair We also include in our repair kit a replacement actuator arm. This is rarely required as the lever is normally the fault, however on occasions this can snap or the ball joint receiver can wear causing issues. In this instance cut the arm off 25mm from the actuator end of the arm. Fit the new arm over the top and screw tight to fasten. Step 7: Test function of the mechanism

30 This completes the repair, test the function of the lever and check all clearances are OK. Before refitting to the vehicle we recommend cleaning the internals of the manifold to remove as much of the carbon build up as possible, this will reduce the strain on the swirl / tumble flaps. Upon refitting the manifold to the vehicle the fault codes will need to be reset. 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 sales@x8r.co.uk. 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 2016

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

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