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1.9tdi sticking turbo vanes - FIX with pics

Discussion in 'A4/A4 cabriolet/S4 forum(B6 chassis)' started by Ollie-B, Jan 13, 2013.

  1. Ollie-B
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    Ollie-B Rockin' Shnit

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    done this today and was blown away with the results - massive performace increase. im not saying this is how it should be done but this is how i done it, make sure your engine is cold first of all.

    1) remove air box - remove air duct pipe, loosen jubilee clip to rubber hose, unplug air flow meter, remove bung that attaches top of airbox to wing, pull air box out the way (no pic)

    2) remove 2x 12mm (m8) nuts holding bottom half of egr pipe to exhaust manifold (no pic but cant miss them)

    3) loosen jubilee clip to rubber hose on rear of egr and remove 2x vaccum pipes from egr (no pic but cant miss them)

    4) remove 6x 6mm allen head bolts from bottom of inlet manifold and pull manifold towards you being carful not to damage tin gasket to egr pipe or inlet manifold and be left with this;
    [​IMG]

    5) take your rubber hose
    [​IMG]

    6) insert here
    [​IMG]

    7) make sure it goes down (not hard to do you can see and feel it go down, see above pics to see how far mine went in
    [​IMG]

    8) next i swapped the top of the can for another that i could use an extension straw with
    [​IMG]

    9) the foam oven cleaner doesnt flow cleanly through the straw so what i had to do was tape the straw firmly to the rubber tube to force the foam into the turbo or this happens
    [​IMG]

    10) squirt in your oven cleaner until you see this (just peeping out of the top and not filling the manifold as you dont want this near you valves but it shouldnt cause no trouble)
    [​IMG]

    11) now i removed egr from manifold and started cleaning my manifold and egr to give it time to work (checked it half way through cleaning them and couldnt see any foam so gave it a top up and worked the actuator a little bit)
    [​IMG]
    [​IMG]

    12) use a screwdriver or hard wire brush to scrape off as much carbon from the inside of the manifold as possible and shake it out then fill the manifold with petrol to loosen the carbon (should be left to soak and you dont have to use petrol it was all i had to hand, carb cleaner or anything similar will do) then once soaked for a while empty manifold of fuel and get back amongst it with your cleaning tool, repeat once more (you just want the manifold as clean as possible)

    13) my egr wasnt so bad just had to clean the underside plunger a little bit

    14) by the time you have cleaned your manifold the foam will have done its work

    15) refit everything (shouldnt need to explain)

    16) start engine - smokey exhast - hold revs about 2k for a few seconds until idles settles - take it for a good blast - DONE

    i may have missed some points and will corect any errors i may have typed whe i read it back through, this worked wonders for me and hope it helps others too
    wish i had taken more pics but when i get busy i just crack on and forget

    you may also notice is some of the pics my inlet still attached when squirting the foam into turbo that is because i removed everything the long way with it being the first time ive done this (egr pipe first to get foam in then i decided to just take the inlet off and do that aswel) BUT i put it all back together as one unit so that is how i wrote the guide to take it off as one to cut the stripping time in half and its much easyer!

    the guide looks long but it is a very very simple fix in terms of stripping and cleaning compared to some other jobs!

    any questions just ask and i will answer as soon as i see the post :)
    Last edited: Jan 13, 2013
    #1
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  2. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    Nice write up, thank you. I'll add it to the DIY stickies.
    #2
  3. Ollie-B
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    Ollie-B Rockin' Shnit

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    Sweet. Nice one
    #3
  4. pink.teg
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    pink.teg Member

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    Cool I had done the egr this morning !!
    But could not find that dam mousse anywhere !!
    So will do the rest other day ! Great read thanks
    #4
  5. pauldazzle
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    pauldazzle Active Member

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    MR Muscle oven cleaner is what most people use. Leave it in for a couple hours if your VNT vanes are actually sticking & causing overboost, or you'll probably have to do it again in a few months time.
    #5
  6. Ollie-B
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    Ollie-B Rockin' Shnit

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    Any caustic foam oven cleaner will do really none are much stronger than any other.
    #6
  7. pink.teg
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    pink.teg Member

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    Yep trying to find foam oven cleaner is being hard work itself !
    will keep look just a very clean egr . Makes the car go better
    #7
  8. Gaz!
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    Gaz! Member

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    Did this today, outstanding results.
    #8
  9. benjie
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    benjie Active Member

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    Thank you Ollie. I have been interested in doing this on my car for ages now - I have no overboost probs, but I think it's good preventative medicine or a car that's on 130k. I've seen guides on the B5 and not been happy enough to try it due to the different engine layouts. Your pictures are really helpful and I may just give it a go now!

    Couple of questions:

    The hole you put the tube down, is it a single pipe, or does it branch out... I don't want to inadvertently put the oven cleaner somewhere it shouldn't go!

    moving the actuator on the turbo... how do I do that?

    thanks
    #9
  10. Ollie-B
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    Ollie-B Rockin' Shnit

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    You cant go wrong with the pipe you can feel where its going, it can go right or down and you can feel it so no need to worry about that. As for moving the actuator i have some long nose pliers with a kick in the end that i could hook under ther rod. Bare in mine the rod has minimal movement you should only move it an inch or so. Dont try to force it. I could get my fingers onto it but it was a struggle as i have big hands lol thats why i used my pliers but any kind of small hook would do. Glad this is helping people :)
    #10
  11. dan_s2k
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    dan_s2k New Member

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    I did this at the weekend, as well as cleaning out the EGR which was filthy. However I couldn't move the actuator to loosen it up, as I couldn't get my hands under it and wasn't entirely sure what I was meant to be moving. Does this mean my Mr Muscle down the turbo was in vein or just not quite as effective as it could have been? Should I have another go and make sure I get something with a hook to move the actuator? Can't say I really want to go through it again...
    #11
  12. Ollie-B
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    Ollie-B Rockin' Shnit

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    Even without moving it youve probly got rid of most of the carbon causing it to stick in the first place i wouldnt worry about it unless you have a problem
    #12
  13. kevinmc
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    kevinmc New Member

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    Thanks for this, I've seen this fix in a few places but the pictures really help.
    Just a tiny question... The actuator on my 2000 A3 has very, very little movement and I'm talking less than a 1/4 inch.
    How much movement should I be looking for?

    i have completed the task but despite the treatment and replacing all the the vacuum hoses it's still going in to limp mode about 80.
    Quick flick of the ignition and it takes off again. Replaced the N95 and at a loss now.
    VAG COM tool only has one fault code coming up and it's the dreaded over boost deviation thing.

    Any help or comments welcomed.
    Kevin
    #13
  14. Kyle.
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    Kyle. Member

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    What are the signs of over boosting?
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  15. Ollie-B
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    Ollie-B Rockin' Shnit

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    Mine did that when my nephew thought it was funny to swap my vaccum pipes around while i made a cuppa. Mine was the anti shudder valve pipe on the egr and the t piece underneath it where the wrong way round. Cant say why that would be your problem....
    #15
  16. kevinmc
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    kevinmc New Member

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    Mine is two fold:
    The VAG COM is giving me a single fault code that relates to positive deviation.
    The second is that the car enters limp mode every time I hit 80mph, it can be lower if the revs are higher.
    Renewed the vacuum hoses...all of them, replaced to N18 and N75... Still hits 80 and goes into limp mode.
    Quick flick of the ignition and it resets cuts out again at 105mph.
    #16
  17. Audi Doodah
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    Audi Doodah Active Member

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  18. Kyle.
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    Kyle. Member

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    I can't get the pipe from the egr to the exhaust off, what would happen if I sprayed the oven cleaner down it??
    #18
  19. AdamNajak
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    AdamNajak New Member

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    awesome write up need to do this to mine
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  20. kevinmc
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    kevinmc New Member

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    Kyle
    everything I've read suggests not doing it that way... I think the metal the pipe is made of will not take kindly to the chemicals in the foam. Also withe the pipe off your 100% sure to git the tube down into the turbo and not in through an out let port.
    Mine was a pig too, 1 nut refused to budge... But a blow torch and a big set of mole grips fixed it .... Stick with it mate.
    #20
  21. mrtinx
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    mrtinx 4 to the floor

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    Ok just read your thread excellent stuff and very interesting,
    I'm currently running a Darkside EGR delete kit with race pipe.
    I used acetone to remove all the gunk from my manifold which was very effective .

    I have a 2002 1.9TDI 130PD Avant my question is Does this car have the varivane turbo ???
    several people have said differing answers so ???
    cheers
    Mr Tinx
    #21
  22. Audi Doodah
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    Audi Doodah Active Member

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    Yes, you have a VNT turbo so you can follow this guide
    #22
  23. mrtinx
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    mrtinx 4 to the floor

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    Thanks Audi Doodah,

    that's that clarified , next stop oven cleaner !
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