TDI in MT's 03 Golf

[TDI in MT]

Well, this is what I'll be doing for the next few weeks: cleaning the intake manifold on the '03 ALH diesel. Not sure if I want to do it or have a shop do it. I probably will do it after I find out it will be over $500 to do the job.

Intake manifold removal is required; it can't be cleaned on the engine.

This is common on VW diesels of its age, mostly thanks to the old low-sulfur diesel but also to VW's way of doing EGR.

[Roadhog]

Easy to do.

[kompressorgolf]

remove it, drop it in a bucket of solvent overnight, will come out brand new, no headache necessary.

[SweaterVest]

If you have a removable egr burn it out! I have never tried this and always questioned its effectiveness but would like to hear a first hand account

[Roadhog]

Don't burn the EGR though, you will ruin it. Burning the intake manifold works great though.

[TDI in MT]

remove it, drop it in a bucket of solvent overnight, will come out brand new, no headache necessary.

And that's what I did. A co-worker had 3/4 gallon of 10-year-old parts cleaner, and I contributed a brand-new 3/4 gallon, then let the manifold sit in the tub overnight. I took it out Saturday AM and 90% of the gunk was lining the bottom of the tub. After letting it dry, I took the manifold to the local DIY car wash and used their pressure washer to rinse it. That got about 95% of the carbon.

I let it sit in the parts cleaner for another few hours, then took it and the EGR cooler to the car wash for their final rinse. Now they are clean!

Bolted everything back together & it does seem to run smoother.

[TDI in MT]

Yay! The car is permanently registered. One $154.25 check and no more visits to the MVD.

[benno3231]

Nice feeling isn't it? You're in it for the long haul now though!

[TDI in MT]

Yeah, I hope so. With all the work I've done or had done to it in the past year, I better be. Fortunately it looks like the bills are getting smaller fast.

Part of my problem is I have this thing that the car needs to be almost perfect. Not showroom, but "good enough" usually isn't for me.

[benno3231]

I can appreciate that. Its not perfect without a manual!!