intake manifold

[Higgins11]

Is there a way to check to see if your intake manifold needs cleaned or replaced ....etc. without spending hours taking it all apart?

thanks
Higgins

 

[Lex4TDI4Life]

You could start by just removing the EGR. You can look into the intake and if the EGR is nasty, the intake will most likely be as well. Takes 10 minutes to revove.

 

[MWVDUB]

Amount of clogging also will depend on your mileage and driving style. If you idle alot or putt around town you generally will have alot of gunk to clean out.

 

[Higgins11]

Well the dealership told this guy i bought it from it needed something done to the egr and intake manafold .............so he traded it

I just want to see if the dealership did it anyway before they took it to auction

 

[cattlerepairman]

Well the dealership told this guy i bought it from it needed something done to the egr and intake manafold .............so he traded it

Wow! Like...ashtray is full, need a new car? I guess that means a good buy for you as the next owner!

I just want to see if the dealership did it anyway before they took it to auction

I would say: highly unlikely. No money/time would be spent on a car going to auction.

 

[Higgins11]

i don't kwow what it is yet this guy is not giving me the full details. I don't know why ... i already own the car........but

I figure they may have cleaned the EGR since they had it off the diagnoss the problem. but I NEED TO KNOW. I'm getting ready to go take the egr off and look at it. I'm also trying to find out what dealer he used

Thanks for the feed back so far .........keep it coming

Higgins

 

[DanEboy]

A really quick peak can be done by just removing the hose that goes to the EGR and looking in with a bright light. You're looking to see how much the inner diameter of the EGR has been reduced by build of of CRUD!
My first TDI a 2000 Auto, at 90k was reduced to about the size of a quarter! I think the previous owner was using regular oil instead of synthetic. Which some say will crud up more and faster.

 

[Canadian_Grizzly]

Here is the link to do your own Intake Manifold cleaning (just do it…really) http://pics2.tdiclub.com/gwillie/VW/Sballintake/INTAKEMAN101b.htm
Also check the snowscreen… http://forums.tdiclub.com/showthread.php?p=1344400#post1344400

Good luck,

 

[Lex4TDI4Life]

...do your own Intake Manifold cleaning (just do it…really)

Amen. I am a mechanical newbie. First thing I ever did on my own TDI was clean the intake and EGR. I learned tons about my baby and she ran like a champ afterwards.

 

[Higgins11]

Thanks for the link canadian grizzly

I think i'm going to jump on that soon and get it done.

I've got another post started about a egr delete down in the preformance section i'm going to wait on the results from that and maybe do it all at once.

 

[Canadian_Grizzly]

Let us know how it goes... one thing go to a tool store and buy a set of metric allen sockets. When you go to remove tap the socket all the way in with a hammer to ensure its seated right. Also have some proper coolant available to top off (you will lose some).
Good luck and you will feel like a champ that you could fix and maintain your own car.

 

[Higgins11]

I do maintain most of my cars(trucks) i've got a f35o powerstroke and a jeep wrangler. This TDI stuff is just all to new to me and i am not sure yet how hard they are to wrench on ..........my powerstoke i climb under the hood and sit on the wheel well but this aint no powerstroke

thanks again

any more comments welcome

Higgins

 

[kiva]

What exactly is an Elephant hose modification?

Never mind I found the answer! (how do I copy a person's post with out doing a "cut & paste")

The objective of the 'elephant hose' is to vent the CCV blow by gasses to the atmosphere instead of letting them condense and form liquids in the intake.

When EGR operates and allows exhaust gasses in to dilute the incoming air charge with inert (i.e. full of burned exhaust) gasses, one of the consituent inputs will be, of course, soot. The soot particles combining with the liquid and/or droplets from the CCV will form gooey deposits in the intake.

So, if the CCV gasses are vented rather than introduced back into the intake, the 'glue' will not be there to allow the soot to gunk up the intake.

Unfortunately, these modifications would never be recommended for on-highway use in the USofA.
__________________

 

[ymz]

...have some proper coolant available to top off (you will lose some)...

Not if you don't disconnect the coolant hoses to the EGR Cooler !!!

Contrary to the instructions in Gewilli's link, you do not have to remove the cooler unless it's plugged and you want to replace it or clear it up... If you're only cleaning the intake manifold (and EGR valve assembly), you can just hang up the cooler using some wire...

Yuri.

 

[Canadian_Grizzly]

Not if you don't disconnect the coolant hoses to the EGR Cooler !!!

Contrary to the instructions in Gewilli's link, you do not have to remove the cooler unless it's plugged and you want to replace it or clear it up... If you're only cleaning the intake manifold (and EGR valve assembly), you can just hang up the cooler using some wire...

Yuri.

Well I guess you learn something new every day...even after doing it a couple times... thanks Yuri.

 

[Higgins11]

how much crude is to much crude in the egr valve

i took the rubber hose off to inspect the egr and see how much crude was there and it had a little on the floor and a good little bit (enough i could easily get a finger full ) on the butterfly

I"m going to take it off and clean it as soon as i can but i need a referance point to say hmmm its about time or **** i need to do it now.

Thank
Higgins

 

[MWVDUB]

When i had mine cleaned at 92,000 miles, I couldn't fit a dime in the intake or the EGR valve. THat was WAY to much crud. In my opinion, any crud is to much as it restricts the airflow to the cylinders. Sorry, I am missed it, but what year is our car as a reference to changing the timing belt?

 

[blhfla]

Cleaning can make a big difference

how much crude is to much crude in the egr valve
Higgins

I bought my 97 Passat with 200k miles and no records. The engine would go into limp mode about 5 minutes after starting. The VERY first thing I did was have the TB/WP changed (next time I'm buying a kit and doing it myself when I can plan it). Then I waited for the weekend so I could do the intake. It didn't really look that bad, mostly buildup around the valve, but perhaps one third restriction. After thorough cleaning it runs as it should, BIG DIFFERENCE. I didn't think it would have that much effect but it did.

I followed this video howto series but did a couple things differently:
http://rushingaround.net/tdi/intake_cleaning/a3_intake_manifold.htm Two things I did differently when removing the intake that worked better for me. One, I didn't remove the bottom of the flexible metal duct (driver's side) from the cooler (inlet side) as one bolt didn't want to loosen, so I just bent/rotated/revolved the top of the flexible duct toward the front of the car, out of the way and then bent it back on reassembly. Two, I removed the cooler before removing the flexible metal duct connecting to the EGR to make it easier to access the bolts connecting the flexible pipe to the EGR.

 

[Higgins11]

99.5

i did find out from the original owner (found a card in the car and called him out of the blue) and he said it had been changed at 60 and 120k

so i'm good to go for a while

thanks mwvdub at least i know now i don't need to park it until i get it done but need to go ahead and do it when i get a minute

Higgins

 

[HODEDO51]

Hey! great article! Kudos for the time and effort!!!!!

I'm going to make a real "DUH" statement here, and say......if I have to replace a bad / blown turbo, it might be a GREAT time to pull the intake manifold for a clean, as well as for the elbow room to make the turboectomy a little easier......since it's never been done, and I'm sitting at 256,000 Agree? Mark

Here is the link to do your own Intake Manifold cleaning (just do it…really) http://pics2.tdiclub.com/gwillie/VW/Sballintake/INTAKEMAN101b.htm
Also check the snowscreen… http://forums.tdiclub.com/showthread.php?p=1344400#post1344400

Good luck,

 

[shake_rattleandroll]

My mechanic checked my manifold and said it was filled with crud and needed to be cleaned. I asked him if there was a way to avoid having to do this a second time and he told me he could set it so that it wouldn't pass the manifold again..something about a computer setting? anyway, I would like to know what others know about this ...it will cost around $250 to get it removed and cleaned and I'd like to avoid having to do this again if I can. Thanks for your help. By the way, I think it must be part of the reason my MPG has dropped from 48+ to 41...he also adjusted the tensioner on my timing belt. Thanks again...

 

[Canadian_Grizzly]

My mechanic checked my manifold and said it was filled with crud and needed to be cleaned. I asked him if there was a way to avoid having to do this a second time and he told me he could set it so that it wouldn't pass the manifold again..something about a computer setting? anyway, I would like to know what others know about this ...it will cost around $250 to get it removed and cleaned and I'd like to avoid having to do this again if I can. Thanks for your help. By the way, I think it must be part of the reason my MPG has dropped from 48+ to 41...he also adjusted the tensioner on my timing belt. Thanks again...

Yes you can adjust the setting with the computer to reduce the amount of flow through the EGR however with the new ULSD diesel we are running it won't be as much as an issue in the future. How bout cleaning it yourself... its a almost fun to try to tackle this one and won't cost you the 250 either.

 

[Higgins11]

will running bio clean it out naturally since bio is acts as a solvent? will it keep it from building up ?

Thanks
Higgins

 

[elric]

'its a almost fun to try to tackle this one and won't cost you the 250 either'

AhhhHAHAHAHAHA....Yup...just did that on my 99.5 Golf! Personally, if I had the 250..it wouldve been yours to do! Sheesh aint cussed like that since I missed an 8pt MONSTER buck...had to listen to people fly up an down the lake just gettin it and happy whilst Im bustin my knuckles!...grin...wouldnt have it any other WAY...gotta LOVE the DUB! try it!..uhh I dunno about bio being able to clean what I got into...it was caked on the outter crust and Oily and messy after that..but it is definitely worth doing!

 

[shake_rattleandroll]

Well, there's no way I am capable of taking my manifold out...I mean, I can change a flat tire, but it's all Greek to me under the hood, so I'll have to bite the bullet and pay the $250! Unless someone has a better idea? Like driving to Ashland and doing it for me for less??.... I still would very much like to know one thing, please: does a clogged and dirty intake manifold have ANYTHING to do with poor mpg? I am at a loss as to why I now get 40mpg when a couple months ago it was 48+ My mechanic doesn't seem to know either. Thanks. Sorry to sound so frustrated, it's just that I AM! :-(

 

[dino_tdi]

clogged intake will definately affect teh mpg, just research man its not hard to clean t hegr and intake and it will definately need it, i just did it on my 04 and there was almost 0 room for air to pass, now it drives like new