Skoda Octavia RS MY11 - New intake manifold, carbon clean, diy walnut blaster 1of2

[elf237]

Disclaimer: This was my experience, make sure you do enough research that you are confident to attempt this. I have written this to help those who are researching or are unsure if they have the skills to do this. I take no responsibility if you damage your car.

Also applies to VW GTI MK 6 and Audi 2.0T (not sure of the models)

Car history -160000 km - owned since new
Major faults - clock spring ribbon broke - diy fix with new genuine part sourced via ebay from EU. Timing chain tensioner failed 120000km Feb 16, chain stretched and fixed by solitaire partly paid by Skoda Aust cost to me $1800. Intake manifold failure April 2018 - P2015 code

Symptoms
It misfired at low rpm and fuel economy was up and power was down. It got worse and worse until the engine light came on.The manifold actually failed at the flap shaft and popped out. This caused the car to have major misfires and run very rough, but it never stalled. I fixed it temporarily by pushing the shaft back in and only driving the car under 3k rpm.
I got a quote to have the manifold replaced and walnut blast carbon clean for $1800 from an independent, needless to say, I decided to diy.

This writeup isn't a how to do, others have done much better jobs see vids and forums threads below, it is more about outlining some of the things that i struggled with and took me a long time to do and I hope by sharing my experience you can save a lot of time.

I used youtube for the overall process, these videos in particular
Humble Mechanic intake removal
https://www.youtube.com/watch?v=c7c35MJq5e0&t=236s&index=3&list=PLuSmZRMiA RcAtRqA-5K1PdEf2sNTml32H
Edge Motors intake removal
https://www.youtube.com/watch?v=Ugh9vPz2Zd8&t=1019s&index=8&list=PLuSmZRMi ARcAtRqA-5K1PdEf2sNTml32H

Also used these threads for info http://www.vwgolf.net.au/showthread.php?13989-Carbon-buildup-on-MK6-GTI-engine-2.0T-TSI

http://forums.vwvortex.com/showthread.php?5200508-CCTA-and-intake-manifold-flap-position-Code-P2015/page2

Parts sourcing
I got parts from the following places
From qeautoparts1 ebay US
Intake manifold Volkswagen Audi A3 TT Jetta Beetle Eos Intake Manifold Genuine 06J133201BH. $240 AUD delivered

Oemvwparts.com Czech Republic
Fuel injector seals, 06J998907D
Manifold breather hose - connecting hose 06H133583F
Air filter element 1K0129620D

RADUM VIC Aust
Walnut shells 20kg fine

Bunnings
Ozito 23kg Portable Sandblaster
Ozito Air nozzles
Ozito 1250W 12L Stainless Wet and Dry Vacuum

Repco
Carby cleaner $7

runautoparts.com.au
Coolant expansion tank V10-0433 and new wipers

Tools and 110psi max compressor - borrowed

I also own the Ross Tech VCDS Micro Can scan tool which I bought to fix recode the clockspring.

Intake removal and replacement
Pretty simple process watch the above vids at least once.
10mm triple square (M10)
The Edge motors video has a different angle so you can see the 10mm triple square removal and access better than the Humble mech video. I struggled accessing the 10mm triple square, you definitely need a ⅜ socket with extension bars and uni joints. The socket kit i borrowed was quite worn which made this bolt removal harder because there was a bit of play in every joint and connection. If I do it again, I would buy a new socket kit. I also removed the throttle body off the manifold before I took the 10mm triple bolt out, it made access easier.

One thing I didn’t do which I probably should have was to completely take off the charge pipe, I couldn’t be bothered jacking the car to get to the bolt underneath. But it is something that both vids referenced above do and would definitely make it easier to get to the triple square.

Continued in Part 2