Badger5EM Tuning
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  1. #1
    Neil_S's Avatar
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    Cleaning out Intake Manifold and EGR

    I have been having some issues with the A4 recently. My local independent replaced a vacuum hose and this had the car back to normal, but this morning on starting the car I had white smoke and eventually the car would stall.

    After doing some diagnosis I pulled the vacuum hose out of the EGR and all was fine. Took the car on a test drive and it was perfect.

    With this finding I thought I would take out the EGR and Inlet Manifold and give it a good clean to see if I could solve the issue.

    One thing to worth noting if your thinking of doing it yourself, best to do this outside as its a dirty job. I did it inside today because of the rain.

    Took about 4 hours with 2 1/2 of that crud removal.

    I used various screw drivers and bendy things to scrape crud out, contact cleaner and wet and dry.

    EGR Before



    EGR After



    Carbon from EGR



    Intake Manifold



    Carbon from Intake Manifold




    And finally me turning into Papa Lazarou




    Car is driving fine afterwards, haven't driven the car with the vacuum hose plugged in, but it drives fine without and now idles find with the hose connected back up. Will properly test it tomorrow.

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  3. #2
    Neil_S's Avatar
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    For those interested in doing this themselves, I took the car apart in the following order.

    1. Remove two screws holding in the black plastic air intake to the air filter, remove air intake.
    2. Unplug the MAF connector and unscrew the jubilee clip holding the air pipe out of the MAF to the turbo.
    3. Unscrew the air filter cover and remove.
    4. I removed the air filter to ensure it didn't get any dirt on it.
    5. Unscrew the two screws coming into the bottom of the EGR (holding a metal pipe).
    6. Unbolt the metal pipe where it connects to the engine and remove
    7. Remove the three bolts which hold the EGR onto the inlet manifold.
    8. Unclip the pipe into the EGR
    9. Unscrew the 6 bolts holding the inlet manifold to the engine block

  4. #3
    icenutter's Avatar
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    Nasty! I've been psycing myself up to doing this job myself for some time.

    How many miles has your car done?

  5. #4
    Neil_S's Avatar
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    Car has done 69k now. It wasn't that difficult, but you need to be methodical and make sure you have a safe place to put all the screws and so forth!

  6. #5
    iyrix's Avatar
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    Bringing this up again as it looks really helpful. Going to do mine on Friday hopefully.

    Does anyone know if i can just leave the EGR valve to soak? Or is it best to keep it dry?
    Audi A4 TDi 130 Sport

  7. #6
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    going to do this myself to when i get time,excellent neil.

  8. #7
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    Gonna be doing it soon too!
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  9. #8
    Avant4me's Avatar
    The're Graphite not black!!

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    This from a 1.9tdi?

    Official Fan Club member No 001!!

  10. #9
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    I be interested how peeps got to the 3rd bolt by the cam cover as I couldn't get any thing in there to undo it, I had to remove the cam cover and one of the bolts to the pipe that comes from underneath the EGR before I could get access to the 3rd bolt. re intake I didn't even attempt this as I was running out of time just cleaning the EGR value.

  11. #10
    deanski's Avatar
    wax on, wax off

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    i had to remove the clip and housing that hold the vacuum pipes. after that it was much easier, I got big old sausage fingers as well.
    A4 B6 1.9 tdi 130. Slowly modding but don't tell the missus.
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  12. #11
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    Good Moaning,

    Thank you for the pics & the guide. I've read its literally 6 bolts that need removing, in order to take out the manifold, just 6? I know how to take out the EGR & the EGR Pipe (a bit of a pain), is that it? And the 6 bolts? Much appreciated for any help & advice

  13. #12
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    Morning all,

    Done it! I just hope I put the intake manifold gasket in correct. My manifold was ok, nowhere near the level of crud, compared to Neil's, then again, the car lives practically on the motorway.

  14. #13
    Leaky Lloyd's Avatar
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    can of 10k boost,, sorted !,

    or a couple of tins on high mileage efforts !!

    swear by the stuff, its a bit like ronseal, does exactly what it says on the tin !

  15. #14
    Gstar51's Avatar
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    Cleaning out Intake Manifold and EGR

    How do you use this 10k boost Lloyd ??

  16. #15
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    Re: Cleaning out Intake Manifold and EGR

    Just spray down the air intake (after air filter).
    Can't see it getting rid of serious build up though.

  17. #16
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    I did this last night, I removed and cleaned straight after a 10 mile drive. All the build up was nice and soft, used a hot pressure washer and it all came out with no effort.

    I cleaned the EGR bit with a toothbrush and heating oil.

    There must have been a near 5mm build up on everything!!

 

 

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