Intake Manifold Wall Thickness

Hello,

'Does anyone have information about the wall thickness of the intake manifold on the ASZ engine? I'm particularly interested in the area near the EGR unit. I want to tap an M8 nipple (homemade) into the casting to measure boost pressure, but I'm a little unsure whether there's enough material present to cut a thread.'

Best regards and happy New Year in advance!


Toby.

Hi,

Do you think this modification is a good idea? The EGR sludge is likely to cause you some serious problems...

Based on my cleaning process, I would estimate the thickness of the coating at ASV to be around 1-2 mm.

In my opinion, the easiest and safest way is to tap into the pressure hose (by gluing on a nipple) or directly at the EGR unit (see Ulf's technical article about it).

Best regards,

January.

"Do it like Jan says, take a look at the AGR unit; there are areas designated for drilling. I did the same thing on my ASZ and installed an adapter from the model-making sector with an M5 thread. It works perfectly."

I haven't really thought about the slime yet, but that's probably a good point. However, I don't have a flat surface in the tube. I'm not sure if it will seal properly and stay sealed.
'With a wall thickness of just 1-2 mm, I don't even need to drill the manifold because I can barely fit one full thread of an M8 bolt in there. It's too risky for me... I was hoping it would be thicker.'

regarding Ulf's article:

I have to first remove the aggressiveness... I don't have time for that .

Sure, here is the translation of the text from German to English:

'Hello,'

toby

ATTENTION: You need to disassemble it; otherwise, how will you remove the debris and drilling residue from the intake manifold? It won't stay inside the slime.

I would have disregarded the residue. The drill pulls out most of the shavings, and what remains as fine dust isn't that harmful, in my opinion. I'm increasingly liking the hose method, but tomorrow I'll make a new fitting on the lathe for it.

Sure, here is the translation of the text from German to English:

'Hello,'

toby

Hi,

The EGR unit can be removed from the ASV (which looks very similar) in less than 20 minutes. Release the pressure hose, loosen all the screws (hexagonal), then unscrew them one by one, and the unit will come out. If you want to remove it completely from the car, you also need to disconnect the pressure hoses from the EGR valve and the shut-off valve. However, I found it easier to remove the entire pressure regulator assembly of the shut-off valve because those hoses are really difficult to detach.

By the way, my connection for the LDA is located in the pressure hose. The fitting is a plastic piece from Bauhaus (less than 1 Euro) that I shortened slightly with a Dremel. Since there isn't a perfectly flat surface, I glued it in place with plenty of Loctite 300 and additionally secured it with electrical tape – it holds very firmly and has been in use for about 13,000 kilometers now.

"At first, I used a different type of adhesive, but it didn't survive the 500 km on the highway and came off at a boost pressure of 1 bar. However, that's not really a big deal because the hole is small enough to carefully continue driving, and it can be repaired without using large tools."

I would also remove the turbocharger boost hose for drilling (it requires two clamps and one screw)! Sawdust will get into it, no matter what type of drill you use.

Best regards,

January.

Hello!

I just finished machining a second nipple out of aluminum. This part has a base plate, then an M8 thread, and finally the nipple itself for attachment. I inserted the whole thing from the inside through the pressure hose and then screwed it in. I also secured it with locking compound.
'By the way, the pressure hose is surprisingly easy to drill with aluminum drill bits! The entire setup works great. You can see all the overshoots and each individual adjustment. The only problem is the shaky needle. Apparently, the 2mm hole in the nipple is too large. I received a T-piece including a reducing sleeve for the display. I'll try using that later and hope everything then works perfectly. If you're interested, I can also take some pictures.'


Greetings and thank you again for your help.

Toby.

Hi,

To dampen the sound, you can also use a piece of foam inside the tube, or create a constriction, as you plan to do.

Images are always interesting – Ulf has a collection of them in the technical articles, and this would fit perfectly with that.

Best regards,

January.

Okay, here are some pictures of the advertisement.
I can choose between 7 colors; you see blue and red as examples. The display is from Mattig and can be purchased via ebei. It costs approximately €34, including the hose and T-piece. However, we can't really do much with that T-piece .

A friend brought the bracket with him from Motor-Show in Essen. Unfortunately, I don't have any information about the manufacturer.

Best regards,

Toby.