Deflap — need intake manifold plug punch tool?

[DWRS4]

My shop is going to deflap the IM on my RS4. They’re knowledgeable independent VW/Audi guys but it’s their first time deflapping an RS4. To get to the screws that hold the flaps, you need to remove 16 plugs. How do you get those plugs back in to the right depth? Do you need to use the 034 plug punch tool (https://www.034motorsport.com/blog/d...34-108-z005/)? Unfortunately it’s only sold as part of their kit, so that is an expensive punch. Or does anyone have a punch tool they’d like to sell?

[emb]

Subscribed - I ordered the replacement plugs from JHM, and plan to do it myself this weekend (I've been having flap-related issues I'm looking to resolve). My plan was just to try banging them out with a brass punch or something, but curious to hear feedback from anyone that's already tried it.

[CrickiKaze]

JHM are taller than the OEM plugs. Check how close the plug is on the inside of the port, you don't want it protruding in to the port/runner. I forgot to check the depth when I punched the plugs out on my spare project manifold but the plug sits about half-way in the hole. Brass punch is all you need.

[DWRS4]

JHM are taller than the OEM plugs. Check how close the plug is on the inside of the port, you don't want it protruding in to the port/runner. I forgot to check the depth when I punched the plugs out on my spare project manifold but the plug sits about half-way in the hole. Brass punch is all you need.

Just to be clear: the plugs don’t need to go back exactly where they were, to the millimeter—as long as they’re about half way in and don’t protrude, it should be fine? Also is it OK to just reuse the stock plugs or is it better to buy the JHM ones (car is stock but now doing the deflap and Jackal tune). Thank you VERY MUCH.

[CrickiKaze]

Correct, assuming the bore is the same diameter they whole length, I don't have a tool to verify that yet but the interference fit felt the same when I punched them out IIRC. I don't know if they can be reused but I would assume they could due to the interference fit, but pending the surface of the plug that interacts with the wall, method of removal and any deformation from it being removed will let you know if you try and reuse them. JHM suggests using a sealant when installing their plugs.

I have a set of JHM plugs on hand when I do my CC. I measure the JHM and oem plugs from the other manifold that I removed as well as the diameter of the port and they are about the same size with the hole smaller, don't remember the measurements.

[longlivenacars]

IMG-3979.jpgPRCc+5A7S%mTdaGd0FdWBw.jpgpVQo1u0rSJOA+erZtYk89w.jpgfullsizeoutput_8.jpgfullsizeoutput_6.jpgfullsizeoutput_3.jpgfullsizeoutput_4.jpgUxqkeqqmRk22pn2AeJ0PEg.jpg

I posted these photos earlier to another thread. I re-used the original plugs I punched out. I did not seat all plugs perfectly with 034 tool, but the loctite has saved me to this day. Some more info. Definitely use red loc tite. Took 3 days to dry on mine for some reason. Maybe bad batch of loc tite. Some of them may look scary level of inwards, but I remember looking in from the back (inside of intake manifold) and they were still flush with inside wall or even pushed out from inside walls of manifold so I just left them.


Some measurement in new attached photo

If creative:

Mig/tig welder

5/16 OR 3/8 bolt (maybe these bolt sizes are right, I can put them up against the tool for anyone that wants to make it to be sure) OR Mild steel cut piece of rod

Thick washer

Tack welds on correct side of washer