Cleaning the EGR and Inlet on a GT

[Greg Roles]

Cleaning out your own inlet isn't that complicated, you will need to buy a decent set of Torx driver from supercheap to do it, and a lot of degreaser, a can or two of carb cleaner, and a lot of rags. Gloves would be a good move too.

For $400 , I'd teach myself!

[poyta]

Well, i finaly took the plunge with 2005 Golf TDi. Its got 131,000k on it so im guessing it may need the intake cleaning! If i was to be lazy, who would you say is best to take it to to get poyta's cleaning job done? The vehicle inspection guy i used before buying the car said he'd done a decarbonisation and inject clean recently and would charge $400, which is a bit steep!

Congratulations on the purchase !
I would ask exactly what that $400 involves because it may just be a decarbonisation spray can job and some injector cleaner rather than the actual physical job of cleaning that I did. I certainly would charge more than $400 for the job i did considering it took me a whole weekend. I can't image a mechanic charging less.
Its takes a while but its actually quite easy to do - if you want you could just avoid cleaning the inlet manifold as this was by far the worst job - the other two parts weren't that bad really. Plus when you finish you'll have a warm fuzzy feeling inside knowing that you've done a good job. You may want to look at adding an oil/air separator like a Provent to prevent this problem in future. Heaps of info on that here on the forum or contact Greg - he's the Provent guru here.

[koolerking]

Cleaning out your own inlet isn't that complicated, you will need to buy a decent set of Torx driver from supercheap to do it, and a lot of degreaser, a can or two of carb cleaner, and a lot of rags. Gloves would be a good move too.

For $400 , I'd teach myself!

True!

Are the manifold heads Torx? (last time i looked at a vw head it was a beetle, 14 years ago and they were hex! )

Can you soak the manifold and ECG with the degreaser, and the attack with a brush?

[Greg Roles]

On the Provent front I've now sourced rolls of silicon hose, and am even trying some black silicon vacuum line hose too! I've a nice cheap drain tap, and I'm at the stage of being able to fab brackets to suit.

The main problem remains, where to mount it in the TDI with the stock airbox, it's a physically big unit.

I am picking up the smaller Provent 150 tomorrow, good for 150kw, and a lot smaller in size. A must for the Polo boys, may be the go for the stock airbox TDI crew too.

[koolerking]

On the Provent front I've now sourced rolls of silicon hose, and am even trying some black silicon vacuum line hose too! I've a nice cheap drain tap, and I'm at the stage of being able to fab brackets to suit.

The main problem remains, where to mount it in the TDI with the stock airbox, it's a physically big unit.

I am picking up the smaller Provent 150 tomorrow, good for 150kw, and a lot smaller in size. A must for the Polo boys, may be the go for the stock airbox TDI crew too.

So would the 150 be fine for a stock 2 liter tdi, 2005? I read in another thread about other cooling mods and EGC deletion (?). Do you need this for the provent 150?

I don't even know if this car will have the DPF thing, or if thats good or bad (my first diesel, so a lot to learn!). The vehicle inspection came bad positive, mentioned the "normal diesel smoke" on hard acceleration and that a decarbonisation and injector clean would help. Im guessing the intake and EGC clean would really help if those pictures are of a 40 (ish),000k engine and this will be on 131,000!

[Transporter]

The Provent200 is a better choice and right capacity for 2.0L TDI

[Greg Roles]

Not if it won't easily fit Miro! Will see when I pick it up.

You can't soak the flap or EGR mechanism, as they have integrated electronics and motors attached. All the bolts on the VW are Torx, but get some nice long ones.

We can easy make up a DIY on this, so save your cash and go visit supercheap.

Oh yeah the only MKV Golf TDI to have a DPF was the GT TDI 125kw. You're free there.

[poyta]

True!

Are the manifold heads Torx? (last time i looked at a vw head it was a beetle, 14 years ago and they were hex! )

Can you soak the manifold and ECG with the degreaser, and the attack with a brush?

As Greg said all heads are Torx. Yeah dont go soaking the ECG - this has to be cleaned by hand- I found using a metal polished worked better than de-greaser. The Manifold however can he soaked because its only a piece of plastic ( although not sure if the standard TDI's is plastic too ) . I had mine sitting in the sink full of degreaser overnight and then later just sprayed degreaser through it will continous flushes with hose. I was amazed at the amount of oil that flowed out of it. Just remember to make sure its completely dry before re-installing it , you don't want to get water in the engine.

[kaanage]

The Provent200 is a better choice and right capacity for 2.0L TDI

Isn't the Provent number indicative of the max kW output for the engine that it should be fitted to? The non-GT/GTD versions of the 2.0l TDi's (both PD and CR) only put out 103kW as stock and probably won't go above 130kW when remapped unless heavily modified.

Some headroom is always nice, though

[Greg Roles]

It's more that the 200 has the lowest restriction of the two, and you want to minimise restriction in any PCV system. In light of that, if you have space, overkill is the answer!

[koolerking]

It's more that the 200 has the lowest restriction of the two, and you want to minimise restriction in any PCV system. In light of that, if you have space, overkill is the answer!

Hi, with these provents do you need to change anything else, i read on another thread you talked about cooling mods, or is that if you chip?

[Johnnojack]

True!

Are the manifold heads Torx? (last time i looked at a vw head it was a beetle, 14 years ago and they were hex! )

Can you soak the manifold and ECG with the degreaser, and the attack with a brush?

FWIW I have found the easiest way to remove stubborn carbon and greasy deposits is with a caustic cleaner, like oven cleaner, draino, or mild caustic soda (NaOH) and water, also some engine cleaners are slightly caustic and more gentle on aluminium. Liquid hydrocarbons like carb cleaner are fairly weak with carbon and only dissolve the grease. Use a nylon brush or toothbrush as caustic will eat up hair brushes and any other carbon based material (like skin) Wear specs and rubber gloves. Method just gently brush on solution, wait a while then rinse off with lots of water from hose. A plastic manifold could be soaked for a few hours then washed spotlessly clean with no damaging scraping or chipping needed.

[koolerking]

Would you say the EGC and intake clean would stop smoking on acceleration?

[Transporter]

Would you say the EGC and intake clean would stop smoking on acceleration?

Definitely not, your Golf has PD injectors that are less precise in controlling the amount of injected fuel.

[koolerking]

Definitely not, your Golf has PD injectors that are less precise in controlling the amount of injected fuel.

Oh, should i be worried what else could be causing smoking through the rev range, with a strange "pulsing or hesitation when the throttle is held around 2-2300 RPM. The rest of the engine is fine, no lack of power. Could it be injectors?

EDIT: its actually only smokes from 2 to 3000rpm on hard acceleration or going up a hill, then its clear.