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Evoheatshield Phenolic Spacer

       
    
    
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EvoHeatshield Phenolic Thermal Spacer kit.
1 EvoHeatshield Phenolic Thermal Space…
 
"Before" picture of Intake Manifold.
2 "Before" picture of Intake Manifold.
 
DSC02617. The dipstick tube is prone to breaking so I picked up a spare for about $8.  Part # 06A 103 663 B
3 DSC02617. The dipstick tube is prone…
 
Various fuel, vacuum, and electrical connections removed and marked.  Fuel Rail lifted up and out of the way.
4 Various fuel, vacuum, and electrical…
 
Bungee cord used to hold Fuel Rail up and out of the way.
5 Bungee cord used to hold Fuel Rail u…
 
Intake manifold removed.  Gasket is still stuck to the head.
6 Intake manifold removed. Gasket is …
 
Another picture of gasket stuck to head.
7 Another picture of gasket stuck to h…
 
Manifold removed.
8 Manifold removed.
 
Throttle-body removed.  Bentley manual recommended torque on the 4 bolts is 10Nm.
9 Throttle-body removed. Bentley manu…
 
Throttle-body.  Bentley manual recommends replacement of the green gasket shown here.
10 Throttle-body. Bentley manual recom…
 
Gasket between Intake Manifold and Throttle Body.  Audi part #028-129-748.
11 Gasket between Intake Manifold and T…
 
Gasket has been removed from Head.  Each intake plugged with paper towels.
12 Gasket has been removed from Head. …
 
1500-grit sandpaper used to removed gasket residue.
13 1500-grit sandpaper used to removed …
 
Phenolic Spacer installed to mark areas of intake manikfold that need grinding for "spacer matching".
14 Phenolic Spacer installed to mark ar…
 
Area marked for grinding on each intake.  This was done to match the Phenolic Spacer.
15 Area marked for grinding on each int…
 
Area marked for grinding.
16 Area marked for grinding.
 
After grinding and sanding.  I used 120, 220, 320, 400, 600, 800, 1000, 1500, and 2000-grit.
17 After grinding and sanding. I used …
 
Closup of finished product.  Each intake tube was polished after sanding.
18 Closup of finished product. Each in…
 
Inside of main body was also cleaned, sanded, and polished.  This picture is early in the process.
19 Inside of main body was also cleaned…
 
Another picture of finished intake.
20 Another picture of finished intake.
 
I used many grades of sandpaper and Steel Wool.  A very small wire brush was used to get down into each intake tube.
21 I used many grades of sandpaper and …
 
Blue painters tape was used to protect the IM.  A small wire brush was used to get down into each intake tube with sandpaper and steel wool.
22 Blue painters tape was used to prote…
 
Head marked with a blue Sharpie to identify area to be removed for Gasket match.
23 Head marked with a blue Sharpie to i…
 
Area marked was removed with a Dremel.  Sanded using 120-grit in this picture.
24 Area marked was removed with a Dreme…
 
Area marked with a blue Sharpie needs to be removed for an exact match with the Phenolic Spacer.
25 Area marked with a blue Sharpie need…
 
After a Dremel was used and sanded with 120-grit.
26 After a Dremel was used and sanded w…
 
This area MUST be cleaned out!  I removed the paper towel with one hand while holding a vacuum.  I used various vacuum attachments to get down and around each valve.  I recommend using a small magnet to get down in there also.
27 This area MUST be cleaned out! I re…
 
Obviously a joke.
28 Obviously a joke.
 
1st gasket installed.  Part# 058 129 717D
29 1st gasket installed. Part# 058 129…
 
First gasket installed.
30 First gasket installed.
 
Phenolic Spacer installed.
31 Phenolic Spacer installed.
 
Closeup of Phenolic Spacer installed over gasket.
32 Closeup of Phenolic Spacer installed…
 
2nd Gasket installed over Phenolic Spacer.
33 2nd Gasket installed over Phenolic S…
 
Intake Manifold reinstalled.
34 Intake Manifold reinstalled.
 
This photo shows the gap between the IM and the OE bracket.  For this reason DON'T REINSTALL THE BOLT AT THIS LOCATION!
35 This photo shows the gap between the…
 
Extra parts included in kit.  You DON'T use the replacement bracket shown.
36 Extra parts included in kit. You DO…
 
Finished.
37 Finished.
 
DSC02667
38 DSC02667
 
DSC02666
39 DSC02666