2.0 TDI Itake and EGC clean-Help needed!

Hi,


So i started the above clean today, i have got all 8 allen bolts out of the alloy intake manfold, (4 short bottom bolts, 4 longer top bolts), but i can't seem to budge the manifold. I have double and triple checked there isn't a bolt left and i can't see one. It just won't move!

I don't want to get to using the hammer as don't want to break the manifold.

Does it need something larger than flat head screwdriver to lever it off?


Any help or idea would be brilliant as im trying to get it clean and back together by monday!

Cheers

EDIT: i read on another forum that there is one bolt in the manifold itself? Is this right for a 2005 20.09 TDI?

I found this sitting on a pipe below and behind the ecg area. I was wondering if its a breather pipe cap of some kind as i do have a very thin film of oil in that area. If it is, where does it usual live?

Thanks!



http://www.vwwatercooled.com.au/foru.../11ag49e-1.jpg

http://www.vwwatercooled.com.au/foru.../06/mi4k-1.jpg



http://www.vwwatercooled.com.au/foru.../10qjnnl-1.jpg

Cue Aydan - gldgti......

Quote:

---

Originally Posted by koolerking

Hi,


So i started the above clean today, i have got all 8 allen bolts out of the alloy intake manfold, (4 short bottom bolts, 4 longer top bolts), but i can't seem to budge the manifold. I have double and triple checked there isn't a bolt left and i can't see one. It just won't move!

---

Hmmm...my GT has the plastic manifold and it had ten bolts, not eight holding the manifold. As you can see from the reverse here -

http://www.vwwatercooled.com.au/foru...P1040159-1.jpg

My manifold came off very easy once I got them all off, perhaps you've missed one, There's one hidden inside that little hole in the opening shown here.

http://www.vwwatercooled.com.au/foru...P1040166-1.jpg

Mines the alloy manifold, I found the hidden one (at first i thought id take the ecg with the manifold in one, the took that off and found the hidden bolt). All off and soaking overnight. It didnt look to bad, i guess its been done before at some point.

Now all i need to do is work out what that clear plastic cap is i found in the lower engine bay! (see above)

cheers

Hi again,

So the egc and intake manifold was cleaned up, i don't think it was as bad as some of the photos on here. Perhaps it had been done at some other point as i was definitely thinking a 130, 000 diesel would be more coked up.

It still has this strange hesitation at 1500 to 2200 RPM if your in manual and you hold it there so the next step is some Morey's diesel smoke killer as im thinking the injectors a quite dirty (it smokes like a champ!)

Is there any special way to use the cleaner, or just chuck it in the tank and drive normally?

i think that plastic cap you found is off a maf, as it says pierberg on it. I think it was from a pierberg maf and this was one of the covers over the end of the pipe put on for shipping and removed for fitting to keep the inside of the maf nice and clear and undamaged.

As for the hestitation, what have you done so far? new fuel filter done? MAF tested ok?

Ah, so the cap isn't anything it needs to run!

I have only clean the ECG and intake manifold. Next is some moreys for the smoking ( i was sort of hoping that ight help the hesitation if the injectors are dirty?). I guess the fuel filter is a good idea as well.

yeah cap isnt needed.

I would get the fuel filter replaced, chuck some good quality diesel in the tank and go for a blast to clear the injectors through, generally cleaners arent needed in VAG diesels, just good quality fuel.

After that i would look at getting VCDS on it and logging MAF and Boost to see whats happening, detailed here :-

Ross-Tech: VAG-COM: TDI VAG-COM Info