EGR should we all be more concerned

[Greg Roles]

mate a typical dipstick low to high is worth about a litre, so I'm looking for a drop of a fifth? I don't watch THAT closely! No doubt it's engine oil, but it's not a concern, nor anything I notice normally!

[Transporter]

Some of that 200ml oil caught in the provent is offset by the unburned fuel, which goes in the engine sump and forms carbon particles. Also other contaminants in the oil will make up for such a small amount of oil lost.
Oil consumption of 0.5L is nothing to worry about.
I always let the used oil to cool down in the drain container before I tip it in the graduated waste container, if I want to check the oil consumption.

I'm not worried too much about my TDI engine failing before 150,000km because of the sludge in the inlet system.
If the VW wants to maintain sale of the TDI engines than that sludge we see in the inlet manifold and the intercooler cannot have serious affect on the engine life (if used and serviced properly). Emission standards in country like USA require the emission system guarantee. Even drivers in Europe would have trouble to pass emission tests or do they all keep the car only for max 2 to 4 years?

[HiTorque]

OK, this is just an update: I got my car back fixed with VWA contributing 50%. I spoke with head tech guy and according to him that black stuff in EGR system is a product of mostly unburned fuel and oil vapor. The car needs to be driven hard with go-go pedal flat to the floor 4-5 times a week when engine is hot, and that will remove those deposits. Flap motor failure wasn't caused by clogging EGR system and that doesn't have any negative impact to the engine. This car is more suited for freeway driving rather than slow crawling across traffic lights. He didn't recommend a catch can for this engine. I will be using S-mode more often for sure.

[twincamsham]

Yes i would agree on the info above, im a firm believer in running an engine flat out under load a few times a week, nothing beats the vacuum created by it spining at its rev limit to suck everything in.
Babying and engine will not make it last longer- most engine were occurs at start up.
It will become sticky glazed up lazy engine. you will get carbon in behind the rings making them no longer a flexible seal rather just a solid ring,
A ring of NoX deposits around your valve stems.

If your oils good and timing belts good you have nothing to worry about- these are why rev limiters/Governers are designed in for protection.
Two good examples i have of this,

I have seen a friends (dads) diesel car literally Dump sparking balls of soot out onto the road when driven hard and it wasnt used to it, thats how caked it was and burned much cleaner forever after,

Last year i went home for xmas and had mums deligtfully basic 1991 1.3 12v toyota starlet to use for the couple of weeks,It just felt gummed up didnt feel like a free engine so Every night i took it to town i maxed it in the road to a balls out 170kmh, after night 2 it took way less kms to reach it. she took it to town the weekend and asked if id serviced it or done anything because she couldnt get over the way it seemed so willing to urge ahead without half the throttle previously required, she thought something was wrong it was to nippy! LOL

Verdict- Drive everything on good an hard !

[Buller_Scott]

Verdict- Drive everything on good an hard !

Hear hear!!!

[chisler]

noob question time,
is the big black pipe the EGR inlet?

[Buller_Scott]

noob question time,
is the big black pipe the EGR inlet?

hey mate,

nope, that's the pipe from the airbox, after the air filter and the MAF sensor (the little plug thing sticking up just to the right of your arrow).

here is a handy little pic that im sure is elsewhere in the forums:

http://media.photobucket.com/image/vw%2Begr/ardy-photo/underbonnet/enginebay-vac-sol.jpg

basically, the egr feed pipe comes from the exhaust back into the intake manifold of the turbo- on my car (polo) the egr feed pipe isnt the easiest thing to see.

hope that helps.

[Greg Roles]

Looks like the new common rail to me.

[chisler]

holy crap, awesome reply guys, thanks

yes thats a common rail, Skoda TDI RS.

just a few more questions:
- The EGR pipe in my pic, is that going back to the turbo? (was hard to see, starting to get dark)
- is it that EGR pipe, and everything it connects too, the pipe getting all the gunk?

I'm also wondering do manufacturers release more detailed manuals? or would I need to get myself a more generic type manual?

cheers.

[Greg Roles]

EGR pipe comes off the end of the exhaust manifold, it actually pinches exhaust charge FROM the turbo. It goes via a water cooler, which is quite advanced, to drop the exhaust temps.

Everything from where that EGR pipe intersects the inlet onwards is going to end up crud covered. That nice shiney inlet manifold will be caked black inside in no time sadly. I found even the throttle flap in mine was black and oily at 30k's.

Erwin online, or Elsawin on e-bay have online manuals, see the manuals section for more info on these. I'd recommed a well planned day on Erwin if you want the best info, but there are no cheap / easy options at this stage manual wise.

[Buller_Scott]

do you guys reckon it would be advantageous to ask the dealer to do intake clean at service?

or is it abit of a case of most dealers wont be concerned with cleaning intake manifolds as result of egr, but rather replacing turbos when clueless soccer moms in their tdv10 touraegs drive in saying that it appears that the car feels slower at 110,000km's than it did at 20k?

i'd like a manifold clean by someone who is more technically minded than myself, but its easy to doubt the ability of the dealer's service department when you see a wall of certificates stating stuff like:

Congratulations John Smith
For passing your certificate of expertise on:
Car Model: VW Polo
Date passed: blah blah blah

It's abit disconcerting......

[Transporter]

do you guys reckon it would be advantageous to ask the dealer to do intake clean at service?

or is it abit of a case of most dealers wont be concerned with cleaning intake manifolds as result of egr, but rather replacing turbos when clueless soccer moms in their tdv10 touraegs drive in saying that it appears that the car feels slower at 110,000km's than it did at 20k?

i'd like a manifold clean by someone who is more technically minded than myself, but its easy to doubt the ability of the dealer's service department when you see a wall of certificates stating stuff like:

Congratulations John Smith
For passing your certificate of expertise on:
Car Model: VW Polo
Date passed: blah blah blah

It's abit disconcerting......

It could be very expensive.
Once the car done 150,000km and the sludge in the inlet would affect the performance the most people would've consider upgrading the car rather than have expensive repair like cleaning the inlet, intercooler and other parts of intake which could possibly need replacing rather than just cleaning.
IMO it will be 200,000km on engine before the sludge from EGR will affect the performance, of course there will be some engines which will clog up earlier than that.

[Mischa]

i'm not too worried about it; when the time comes ill just clean the sludge out. taking an intake manifold off isnt a big deal. and if its so badly caked on you can just burn it off or sandblast it out; not sure what parts you are referring to that would need to be replaced transporter?

[HiTorque]

i'm not too worried about it; when the time comes ill just clean the sludge out. taking an intake manifold off isnt a big deal. and if its so badly caked on you can just burn it off or sandblast it out; not sure what parts you are referring to that would need to be replaced transporter?

It's not quite easy like that. The "tubing" from intake goes all the way down where apparently there is an intercooler then it comes up and enters EGR flap motor section. You can disconnect tubing at that point and stick you fingers into it and up towards the EGR flap motor. You will see how much black stuff you collect there. You will have EGR valve just above it and when you dismantle that son of a bitch you will hate everything in that car... Get two O-rings to replace and a can of either degreaser or BBQ cleaner or carbo cleaner to remove that sludge. Perhaps tubing under the engine is accessible if you raise the car.

[neil]

Come across some interesting EGR vids.
This one is a device to fit to fool the engine management.
Have a look to the right on this link to related Vids and you will find plenty.
Some great DIY on cleaning the EGR intake maniflold.

http://www.youtube.com/watch?v=_hlJrO78V8I

This is a good one. Be interested to see what our more expert guys think.

http://www.youtube.com/watch?v=iL-6R-8ACe4&feature=related