TDI Owners, be aware of this issue with the DI and PD engines EGR system

[mwilson]

As I learn more about TDI's in general and perform some needed upkeep on Gizmo I stumbled onto this issue. Maybe some of you have encountered it already but want to make sure that you all are aware.



Due to the design of the EGR system and the Crankcase venting into the intake manifold the EGR and manifold will plug with an oily black sludge. Gizmo had a dead spot about 3000 rpms accelerating up from a dead stop. No dead spot if cruising along.



After a little research I decided to pull the intake apart for cleaning.



This is what I found... ... ... .



The intake manifold just beyond the mounting point of the EGR valve

And the EGR valve itself... ...

Needless to say, the dead spot is history... ... . after a lot of scrubbing, removing the intake manifold and burning it out with a propane torch and shop air!!!!



Gizmo has 140,000 miles on it and I don't believe that it was ever done before. Would be a good thing to do during a timing belt service for example.



Mike.

 

[HBarlow]

I think I vaguely remember reading about that needed service on one of the TDI websites suggested by owners here in TDR. Probably very few owners know about it or ever have the cleaning done.

 

[Mikey-KE7LBB]

Replace the belt asap!

I once had a '98 Jetta that had just over 100k on it. Great car and I often miss it, but the little bugger cost me dearly once when the timing belt broke about 10 miles away from the dealership to buy... Drum roll please... A timing belt!! #@$%! BTW... I found out that the valves DO make contact! :{



While I was busy replacing the head (and buying specialty tools to allow myself to do so), I re-routed the breather (elephant hose), effectively disabled the EGR with a VAG-COM and then deleted the stupid EGR entirely.



I found out how to do all of this on http://www.tdiclub.com/... There are lots of VERY smart people on here that may even give the VW engineers a run for their money.



Edit: I forgot to add the issue with the hiccup I had with the EGR being plugged up before I got on my rant about the belt. And IMHO, replacing the belt should occur anytime EGR issues, thoughts of cleaning EGR, or even nightmares of a broken belt may cross your mind!

 

[mwilson]

Having thoughts about complete removal myself, but wanted the experience of cleaning up the mess just to say that I did one... ... .

And let me tell you, it was a mess... . that intake burned for a good 5 minutes. The wife and grandkids snuck up behind me just after I got it lit (I guess they saw the black smoke), tried to put it out until I could get them backed up a little. Well, there was no putting it out. Figured the two boys may as well learn how it is done at that point. Put the shop air to the intake port and was burning grass about 8 feet away just like a 4 port flame thrower. Oo.





For those who have never witnessed such a thing look here... .



http://www.youtube.com/watch?v=oet4qWeZuYA&feature=player_embedded



Or here. . (my manifold is like this one, egr is not part of the intake manifold like the one shown above)



http://www.youtube.com/watch?v=3vOCwB2onGQ&feature=related





Boys thought that was pretty cool. After it finally went out the question was "can you do it again, Beemps?"... ... ...



Have been waiting to pull the trigger on new electronics from Auto Ingenuity, now I had better add the Vag-Com software to the list. Woo Hoo...



Timing belt is at the 80,000 mile mark right now and when it was changed previously it was upgraded to the 100,000 mile version with heavy duty idlers and such. I am going to order the tools in a month or so and plan to change it out before Christmas.



Very happy with Gizmo so far, have put 3,000 miles on it in a month. Has used zero oil and is giving me a solid 38mpg. I expect improvement now that the intake is clean. Will know by the end of the week if that is the case.



Mike.

 

[DAN V]

I have just under 10k on my TDI. The belt on mine does not need replaced until 130k. I guess I have quite a ways to go.

 

[Bill Lins]

Put the shop air to the intake port and was burning grass about 8 feet away just like a 4 port flame thrower. Oo.

That's just too cool! Are you sure you weren't a Texan in a past life? ;-) That's a "Hold mah beer & watch this!" if I ever saw one! :lol:

 

[mwilson]

That's just too cool! Are you sure you weren't a Texan in a past life? ;-) That's a "Hold mah beer & watch this!" if I ever saw one! :lol:

Ha Ha, I have always felt that I could fit in if I ever moved down. The Maine accent would give me away so I couldn't talk much for the first year or so... .



Mike.

 

[BIGNASTY]

EGR and the car is supposed to RE-BREATH this stuff. Cant be real good for the motor I sometimes think that the IG O NEERS have out thought themselves on this kind of stuff. Motor is screwed up but the air she is putting out is clean-er.

Buddy came buy for a visit and bring my TOY form PA to me. He changed his oil and fuel filters on his truck in my shop he had to remove a bunch of body parts just to get to some of the filters. What junk the new International BIG TRUCKS are cant even remember what it was called I was so impressed with it.

 

[Regcabguy]

I put 245K on a '92 Hino 4cy w/Allison non-electronic auto that was the most dependable vehicle I've ever driven. I retired but the Hino's still running strong.

Unfortunately,CARB and the EPA is requiring the school system I worked for to replace the older trucks and buses with newer "clean",dpf and egr equipped vehicles. International Workforce cabovers have replaced the trusty,no smoke Hinos. The energy and raw materials expended along with 30% less fuel economy makes for a real folly. Where's the gain aside from robbing the taxpayer again?

 

[kkelley]

Hey, another VW owner. I havn't owned a TDI, but did have an old Rabbit diesel.
Those EGR pipes are a maintenace item on VW TDIs even though it's not in the manual. I've heard as soon as 40k mile intervals for optimum performance. They do great things for the emissions, but sap power and efficiencey.
Also to look at if you still have it apart, the turbocharger. You should have what is called a VNT turbo. It is simmilar to the new Holset VGT turbo on the Cummins. It needs to be driven hard a lot to keep the mechanism from getting locked up with soot. If you do start to throw boost pressure codes, don't just replace it, try pulling it and cleaning out the actuating system first.
Sounds like you're on your way to a loving relationship with your car. I've had my 01 GTI for over 8yrs and it's got 160k on it, these cars have a bad reputation in the reliability department, but they aren't any worse than any other car's I've worked on.