Good job on the bracket JETaah. Maybe you can give us some details so I can make one for my car. I remember when you've fixed my failing hood insulation using welding wire. Simple but ingenious!
Everything wears out. PD is a wear engine on everything - be it cams, egr coolers, DMFs, injectors, cylinder heads or even intercooler hose clips and hoses themselves.
At that mileage you might have wear on injector bores on the cyl head. Worth checking.
Injectors typically last a bit longer but it's not uncommon to see a work injector or two at that miles also.
BINGO!! EGR delete. I have one and I don't have this problem. And I don't care what anyone says about this being normal or OK. I don't want a bunch of build up like that in my intake.
The walnut shell blasting solution I found on https://www.youtube.com/watch?v=NnMhNXXawjk appeared to me to be the best way to clean the intake ports in the cylinder head, but in order to test this, I decided to try it on something other than my car. http://www.cylinder-heads.com/ was near to my location, and I was able to buy a bad BRM cylinder head that had similar carbon intake port buildup to experiment with.
After experimenting quite a bit with a process similar to what the BMW Youtube video showed, I have concluded that this method is indeed very useful. This has been an iterative process, and I believe that I have finally arrived at a final, workable iteration.
I am curious whether or not anyone else here has already used walnut shell blasting to clean VW TDI cylinder head intake manifold ports, or, discovered definitive reasons why this method should not be used.
The 4th picture shows a 1-1/4" PVC Schedule 40 street elbow patially reshaped with a vise after being boiled in water and by cutting off most of the smaller diameter length and, with duct tape diameter adjustment, fitted into a shop vac hose. The shop vac air volume greatly overwhelms the air volume from the compressed air carrying the walnut shells at high velocity into the port, so there is no leakage of walnut shells either during or after the blasting action is discontinued. Straight compressed air gets the last few grains out.Stupid question, but how do you get the walnut shells back out of there? Looking forward to updates on this.
Wow I've been trying to find a thread like this for months! Really enjoyed reading your investigtion and the results are clear as day from the photos. How much have your MPG figures improved since?My TDI is finally running again, and performance is excellent. No smoke, excellent power and response, no CEL codes, no problems. It is SO GOOD to have this car back in service and running well. However, since the work on this engine included both replacing the cam and totally cleaning the intake path, performance gains cannot be attributed to a specific change, such as having cleaned the intake path.
I will update the anticipated fuel economy improvements after a few tanks of diesel.
While dealing with this, I pondered various methods of preventing intake fouling. The most appropriate method is to make certain that everything is operating correctly. In my experience, this cannot be easily done with this car because it is structured so resiliently that it will run even with numerous issues, some of which will cause gunk buildup. So then I thought, what if the intake path was too slippery for anything to stick to? This train of thought led me to researching methods for steel and aluminum surface treatments that would simply be highly resistant to having anything stick to them in the first place. There exists such treatments available out there. I am looking into experimental methods of determining whether or not these would work.