Cleaning the EGR and Inlet on a GT

[poyta]

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.

Sounds like its normal to me - they all smoke under hard acceleration. Unless you have a DPF filter which your car does not.

[neil]

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.

What fuel are you using. Try changing fuel companies.
You could try BP and I think some caltex have the new higher rated vortex diesel in Sydney.
I only use the good stuff from BP and still get the puff of black smoke when you hit
the accelerator hard but that's what I like to see out the back.

[koolerking]

Sounds like its normal to me - they all smoke under hard acceleration. Unless you have a DPF filter which your car does not.

Thinking about it its probably not even under hard acceleration. In fact hard acceleration gets it "though" the smokey bit of the rev range. it seems to do it even up a gentle incline. It makes me think its when the turbo spins up, which could equal major problems, maybe the turbo seal?? Hope the new car isn't turning out to be a certain fruit.

[gldgti]

probably its just regenerating the dpf... or trying to.

[koolerking]

probably its just regenerating the dpf... or trying to.

I didn't think the 2005 2.0l TDI's had a DPF, is that right or wrong?

[stickshift3000]

I didn't think the 2005 2.0l TDI's had a DPF, is that right or wrong?

Unless you have a DPF filter which your car does not.

..........^

[Golf]

I've been reading these forums and I got quite concerned about whether the EGR valve needs a clean. I've got a 2005 103kW 2.0TDI (BKD) with 100,000km on the clock and the EGR valve has never been touched.

So I decided to clean it. It was such a non-event. It's only attached by three bolts plus the two bolts on the exhaust inlet pipe. It took about 2 hours (and half a can of degreaser) as I was pretty relaxed and taking my time. My EGR valve had about 1-2mm of deposits on it, which is really no big deal.

People on this forum make EGR seem like a big scary monster that's going to kill your engine, but it really isn't.

I drive my car about 50kms average every day. I drive a mix of stop/start and highway every day. I don't baby it and I don't flog it.

I think it's a good idea to clean the EGR valve every 100,000km or so, but it's nothing to get too concerned about. VW designed the engine with EGR, so I think it's a lot better thought out than some people seem to think.

I didn't have the time or the motivation to clean the manifold, that'll be a job for another time.

Photos (sorry for the bad quality I only had my phone camera with me)

[poyta]

People on this forum make EGR seem like a big scary monster that's going to kill your engine, but it really isn't.

I don't remember anyone saying its a monster thats going to kill your engine , its just that there have been stories of them getting jammed with the gunk and then sh$%ting themselves. The replacement cost is quite high so a routine clean like you did is a good idea. If you just do your EGR then yeah its quite simple - its the manifold for me that was the bitch!

[Greg Roles]

Little wonder my car feels totally different, what a restrictive point!


Appreciate seeing the 103 version, glad you had a good experience.

[Golf]

I don't remember anyone saying its a monster thats going to kill your engine , its just that there have been stories of them getting jammed with the gunk and then sh$%ting themselves. The replacement cost is quite high so a routine clean like you did is a good idea. If you just do your EGR then yeah its quite simple - its the manifold for me that was the bitch!

I was only having a dig, I have heard of the valves getting jammed and failing, hence why I decided to give mine a clean.

It looks like your EGR valve had significantly more deposits than what I found on mine. My guess would be that the 125kW motors are generally driven harder, resulting in higher EGR to lower combustion temperatures, and that in-turn produces more deposits as the EGR valve gets hotter and more oil vapours get burned onto it.

[Greg Roles]

Blowby is a function of peak combustion pressure too, so with a slightly higher combustion ratio ( 18.5 vs 18:1 ), and higher power output, you naturally get more blowby. Having a DPF on the other side choking things up can't help either!

Bottom line like I've always said the MKV 103 without DPF can get away without a can, as the oil just gets burnt, but the GT and MK6 cars with a DPF are mad not to run one, given it is oil ash that blocks these babies up ( largely ). Clogging up the inlet would only worry the performance orientated drivers, and those keeping the car beyond 100k -kms.

[Dam355]

EGR cleaning

Hi i have a 2005 103kW 2.0TDI which has done 206,000km. I cleaned the EGR inlet and manifold yesterday which took around 2.5 hrs to do. It was not as clogged up as i thought it was going to be. The manifold was fairly dirty and had a lot of soot and crap in it.

Just remember the bolt in the opening of the manifold, I would never know it was there as it was covered up with soot. Thanks to this forum for letting me know.

It was a filthy job cleaning the soot and crap out of it!


IMG_3436.jpg by Dam355, on Flickr


IMG_3445.jpg by Dam355, on Flickr


IMG_3447.jpg by Dam355, on Flickr


IMG_2680.jpg by Dam355, on Flickr


IMG_3461.jpg by Dam355, on Flickr

[benough]

Good to see people getting into it.

I might have a crack this week.

[gldgti]

" It was such a non-event. It's only attached by three bolts plus the two bolts on the exhaust inlet pipe. It took about 2 hours (and half a can of degreaser) as I was pretty relaxed and taking my time. "

"People on this forum make EGR seem like a big scary monster that's going to kill your engine, but it really isn't."

The fact is that EGR buildup can cause serious problems, and people should be aware of it. The kind of regular driving cycles that the engine experiences, the oil used and a few other factors affect EGR build up, but just because yours wasnt too bad after 100,000km doesnt mean thats the case for everyone.

I've personally seen and cleaned egr deposits up to 5mm thick, and i've seen them caked onto inlet valve stems so thick that it was just a nice tapered cone shape from the valve guide to the back of the head of the valve. when large deposits are loosened they could certainly be caught between the valve seat and valve, causing piston/valve contact and loss of compression.

The other thing to note is that you have only cleaned the uppermost part of the system - the inlet manifold is still clogged as before. And trust me, the inlet manifold is a lot harder to clean than the throttle body.

[benough]

As I don't have ETKA, is someone able to post up the part numbers for the gaskets?

So gaskets for the manifold, EGR, EGR pipe?

We all know our local parts interpreter is a shaved chimp

Thanks

Ben