Cleaning intake manifold on 06 Passat TDI (BKP)

[PranK]

Hi Guys,

We recently bought an 06 Passat TDI, its a BKP code (so, PD I'm assuming?) which is the 103kw/140hp engine.

It has 120k's and has been regularly serviced by a local non-vw mechanic.

The few tank's of diesel it has drunk so far have yielded an avg of ~8.5l/100 (or 27.6 mpg) which to me seems high. It's also been a little hesitant to start once or twice and these two issues scream intake manifold cleaning to me, but all the info I find on the intake manifold suggest that it was not a problem with our car and was more the earlier 1.9.

I was also considering installing a Pro-Vent (catch can) but again, I have only found (good) information from people installing these on the 1.9's.

So, my questions, in a nutshell; Is it worth taking the intake manifold off (which seems harder to get to than the 1.9's) and cleaning it and the EGR? And, is it worth fitting a catch can also?

[ This post has been posted on tdiclub too, but nobody replied there so i'm reaching out to my local folk for help ]

Christian

[transporterq]

I have a 07 Passat, average mileage for me is around the 6.5/100 and that’s for city driving, I can knock off another litre in the country.
From what I can see off the TDIclud site, it seems to be more American, I believe they had the 1.9 L engines, but do not believe they had the B6 Passat, with the 2 L diesel, happy to be proved wrong.
I believe that for any diesel engines, you are better off to clean the intake manifold, they do build up with a lot of rubbish which restricts the gasses from leaving.
I am also considering installing a catch can, not a Pro-vent, I am just waiting for my APR cold air intake to arrive to free up some space under the bonnet first.
I have read that a cold air intake will not do much to help either performance or mileage, like I said, I just want some extra space to help install the oil catch can.
I have fitted an APR S/S 3” exhaust system from after the cat back, I am thinking of replacing the cat with a hi/flow 3” S/S one and then removing the EGR value, but I believe this will throw up error codes and as I do not have access to the computer system, would be unable to sort them out.
The best way to really make a difference to the performance of the car would be to upgrade the computer program, lots of info about different ones here on the site, it really depends on what other mods you have plan and the budget you have to work with.

[PranK]

Unfortunately for me (and the car) it belongs to my wife who has a similar relationship with car modifying as the South Koreans have with the North. They are like oil and water.

I have convinced her to let me fit a provent because its good for the car, but thats pretty much it. I'm also keen on removing the EGR but dont want error codes, she will be less than pleased with that.

I was under the same impression re the intake manifold, it would be beneficial on any Diesel. I'm not sure how easy it is to get to though, so will need to consult the manual. I have a few days off this week so wouldn't mind giving it a go.

Thanks for the reply.

[transporterq]

There is one thread called "Cleaning the EGR and Inlet on a GT" under the diesel section, may be more, will give you at least some idea as to what you are looking at.
My wife has a Mazda 121, will not even let me update the radio, expects me wash, polish and wax it though.
Thankfully the Passat is considered mine, so I can do with it as I please, as long as the price is reasonable.

[PranK]

Gah, not sure how I missed that! Great thread! Thanks!

[benough]

Hi there.

When I cleaned all of mine out, I got an extra 1.5L/100km on the freeway, city was about the same.

It's a b4stard of a job but worth it IMO. Plus you get extra man points for being dirty as. That said, don't do it onto you lawn or concrete, I still have dead patches...

[PranK]

Well, pulled the EGR off today and its almost clean enough to eat off. Must have been cleaned recently.

Air and fuel filters are the others that could help my consumption... Not sure what else to check.

[stickshift3000]

That consumption does seem too high. It might be worth running a scan to see if it's thrown any error codes.

It could be anything from a clogged air filter to a faulty injector...