Audi A6 S6 V8 4.2 Intake Manifold Rod like 077198327A

On my Audi A6 4B with a 4.2-liter V8 engine, one of the intake manifold's connecting rods broke. A replacement part for it can either be found in poor quality plastic for a lot of money (it will break again) or in metal. I didn't like the idea of mounting a metal connecting rod onto a plastic ball joint, so I quickly designed this model. 

It works exactly like the original part, which has the part number 077198327A. This number is for comparison only. 

In my Audi, the long variant is installed; there are also engines where a short connecting rod is fitted. I would be happy to design a corresponding model for it if you provide me with the dimensions.

It is important that the model is designed for printing with PA6-GF to withstand thermal and mechanical stresses. The tolerances are very tight, which is why problems can occur especially when printing with other materials. I strongly recommend using PA6-GF.

I have been using the connecting rod for over 1000km without problems, and thus the model solves a recurring issue in vehicles with 4.2-liter V8 engines. 

For a complete replacement on a vehicle, you need a set of 2 rods, corresponding to one print plate.

Before installing the new rods, you should ensure that the flap mechanism inside the intake manifold is functioning perfectly. 

After removing the lever, you can carefully disassemble the aluminum bearing on the front side. Often, the bore where the flap is mounted is somewhat oxidized, making the flap difficult to turn. With some sandpaper and grease, it can be made smooth again. However, be careful with the sealing rings so as not to damage them.

Good luck and enjoy the newly gained performance of your vehicle!