TDI EGR & Intake Manifold cleaning

How I spent my Saturday: removing and cleaning out a gunked up Exhaust Gas Recirculation valve and the gummed up Intake Manifold of my 2002 VW Jetta TDI. The job is pretty straightforward, ONCE you have the manifold off the car. Bookending that is a lot of fishing for bolts with a mirror as everything is at the back of the engine bay. I do love this car though... 140,000 miles averaging about 49 MPG (best 69.7 MPG, worst 42.3 MPG.)

Music is apropos: "La Muton Noir" by the Paperboys ;)

Category:

Autos & Vehicles

Tags:

• VW
• TDI
• EGR
• Intake manifold
• chuck goolsbee
• repair & maintenance

[chuckgoolsbee]

I printed it from the TDIclub HOWTO section.

[TheWorldGatekeeper]

i have octavia with 300000km

i pretty sure that the intake manifold like 150 kg fat man closed heart vein

does that make significant power lose ??

[chuckgoolsbee]

Power Loss? Yes.

[newpoetic]

thanks for the video...  im about to slay the same dragon. what did you use to clean her out?

thanks again, a

[chuckgoolsbee]

Berryman's Chemtool worked like magic. I started with some hand tools and just scarped out the big hunks. Then some brake cleaner I had on hand, but it didn't work too well. Made a run to the parts store and bought the Berrymans.

[thelynx000]

@rsfeller my overall average is 45mpg.. On a long run I get 60-65mpg around town 45-50

[surfstev]

should have said non coated, not non braided in my last comment.

[surfstev]

video was useful to show me how the passage ran. I purchased an assortment of various 2 foot pieces of braided, coated and non braided aircraft wire. The 1/8 inch was the most helpful size. I put vise grips on the other end and twisted and pushed it in and out like a roto rooter, blowing out the carbon with compressed air and carburetor cleaner. Had to take off the exhaust manifold and the egr valve. Both the head and the intake were clogged with a ton of carbon.

[imyanggers]

Hey Chuck, what printout were you following ther to do this job? I need to clean mine too. Thanks for the video.

[rsfeller]

I've had two tdi (1z) and sometimes I question these MPG claims. Mine were rock solid on "average" mpg at 41 and 44 over the life of the car...just not sure about this 70mpg best claims!

[biggurs]

i have a bmw 1997 diesel with 790,000 MILES!!!!!!

i am in the guiness book of records

Ive never even serviced it once!!!!!

[airtexaco]

Just did this to my 2002 Jetta TDI yesterday and hope it improves the mileage. I never got that great of mileage and hope this does the trick. Please let me know how yours did after.

[nutzuXL]

today i cleaned my egr :) i have a 1.9tdi 110hp seat whit 217.000km . there was a layer of 0.7cm of dirt on the inside walls :)))