When replacing the egr pipe back into the manifold intake which way does the piece with the hole in go . Does it face towards the engine or does the hole face the throttle body .
Great work. Will be attempting this myself soon on my b7. Just replaced glow plugs but am almost certain it needs manifold cleaned. Thank you for this. 👏
properly executed repair and well-filmed video! hats off to you! I would have tried to take out the glow plugs with the engine still warm cuz then it is easier but I don't know if you did that so I'm just saying
Removed my manifold on same engine 2.0 tdi 170bhp cega engine. After refitting and vcds fuel priming it just wouldn’t not fire and no fuel pressure. Even with a vac pump on return lines we still couldn’t get fuel….. I’ve got to swap in-line electric fuel pump next week and now dreading it.
How would you remove the glow plugs if you had to do the job again? Could you remove the top off the glow plug, and introduce a cold fluid to shrink it a bit (eg a compressed gas)? Also, running the low pressure pump will prime the high pressure lines?
One question: Did you purge the high pressure diesel line using Vagcom alone? Isn't it necessary to loosen the tubes that go to the injectors and then tighten them when they release air? This is the part that I have the most doubts about, because if a lot of air enters the system it is very difficult to remove it. Thanks for the video, very well explained.
egr valves are a nightmare.. had same process done on my corsa.. btw some people from australia use the spray for oven cleaning and it had excellent results with the soot. i will try it with a kamiq when they day comes to do this work
@@dionich Don't use oven cleaner on sealing surfaces on aluminium, it will corrode the surface because oven cleaner's alkaline. It doesn't remove a lot of aluminium but it's enough to destroy valve seats in the cylinder head. No problem using it on steel and probably ok on plastic intake parts.
Great video. Thanks. I have seen in other mechanics videos, to prevent the glow plugs from breaking, WD40 is used and left to act for an hour, the block is heated with a heat gun and when unscrewing, the spark plug is cooled with gas, either a CO2 cartridge or any other spray that cools it quickly. Then when assembling it, I ask: Would a small layer of copper grease be good to prevent it from sealing again?
We did forget the heating indeed. This could have helped. Not sure about the copper. We used glow plug paste on the thread, probably this should be enough.
Well worth watching this very informative video.Brilliant spanner work &video.Have removed & cleaned throttle body & egr to get my engine to run decent .Next job inlet manifold to completely DECOKE all the crazy gunge Sh-t....👍.
Definitely a great video, very informative!... I'm actually gonna need the same exact helicoil size you're using for the glow plug repair I'm doing... Thanks for the recommendation brother!!!🤟
Very good work. Did this happen due to faulty egr valve or its common by 75000 kms above vehicles? Also recommended to get engine intake valve cleaned ?
Thanks. This is a standart operation of egr system - to shit up your intake. Cleaned my e91 320d years ago, same story. Its better to clean the valves as well in the engine head, this will smoothen the airflow.
Greeting. First, let me praise the great effort and detailing. Well done, really! I have one question - I have a passat b7 2.0TDI 125kw 4 motion, engine tag CFGB. Belt replacement was done, with all spanners and tensioners, water pump and line belt. After that, the car consumes at least 2-3 liters more. Is it necessary to synchronize the high pressure pump together with the intake cam? Because I'm afraid that the mechanic didn't do the synchronization, because he didn't use locking tools (for crankshaft, cam and pump). He just marked the crankshaft with a marker...
Hi, thanks. We are about to do this job in the coming months. As far as I remember from the manual, the fuel pump needs to be also locked with a special locking pin. Cannot suggest whether the pump should be synced or not, I don't know the mechanics of those fuel pumps. It could be also that your mechanic lost the proper ignition timing whilst not using locking tools.
@@dionich thanks for your reply! the car starts quickly, just like before changing the belt, only the consumption is higher by 2-3L. before he was spending about 7-8L in the city, and now it goes over 10-11L. so I'm afraid that something is not synchronized properly.
@@radulepghi man, we have the same story and I'm thinking to do a timing belt adjustment with hp, my mechanic man told it doesn't matter to time the hp pump but i think i have a high mileage with black smoke, any suggestions about your story?
@@aveirozinou2919 I haven't touched anything on my car yet. I left it as is. I don't have a problem with morning ignition, so I didn't work on it. I don't have any black smoke, the car runs as it should. Except that, a little higher consumption. Check injector parameters, through diagnostics, to be sure that the problem is not with them. Basically, everything should be in sync, because that's how the factory made it. But I'm not sure if your black smoke is from an unsynchronized pump. How does the car work on idle? Is it shaking?
@@radulepg no shaking no hesitating, car works fine even when you rev the car answer fast, but i think the way my car start is different from before i changed the belt, black smoke is before and after i changed the belt, but with high mileage consumption than before, so my question is does a timing belt adjustment for hp is required or not
You can start preparing for this job. I did several previous diesel cars with 240-260k kilometers including this passat. They looked the same, all clogged with soot.
I'm gonna spray seafoam into intake pipe at 2500 rpm. Then after 10000 km do it again egr delete at 200 km I'm at 370 km now but I looked into the throttle body and it only had the tiny amount of oil on the lip. Very clean and never cleaned before. TDI 2012 jetta
@@dionich , surely metal filings will get wedged around the old plug and cant get sucked out, when you do vacuum around that old plug its not going to be able to such it all out. I cant believe that no metal filings will fall in with this process. Additionally at this point its the right hand plug hole: ua-cam.com/video/sTn4KLAf-vk/v-deo.html Then at this point in your youtbe you are dropping it into the left hand hole ????? ua-cam.com/video/sTn4KLAf-vk/v-deo.html
Hello, i have the same engine and I'm suffering from black smoke when accelerate from idle to an rmp number (so that happen when you accelerate not when you hold the rpm), i chekcked timing belt its okay, i added injector cleaner and checked injection timing by vcds all okay, new filters of course, changed maf sensor and i still have the same problem, i also cleaned egr and catalytic converter, any help!?
Hey. Black smoke is mostly due to rich mixture. Intake air filter clogged or injectors leaking. Check the intake hoses, manifold with smoke test as well.
@@dionich thank you for the reply, all filters are new, maybe intake manifold leaking i will go for it, please tell me do i have to check the timing of the hp fuel pump or it doesn't matter
@@aveirozinou2919 Not sure wheter hp pump timing is essential, although we are going to replace the timing belt ourselves in September and I remember according manual that hp pump needs to be locked with a pin as well as the camshaft.
@@dionich thank you for fast reply. i turned the key to contact a few times, and cranked it 3 times for about 5 seconds and it turned on on the 4th try. definitely wouldn't recommend though. my car is a 2012 audi a3 8p 1.6 tdi. about 5 hours of work including good cleaning i followed your tutorial and my car works like charm now, thank you very much..
no need VCDS or any other OBDII tool for this procedure. Just turn 5x the key in position for about 10 secs. Pump will do the same as VCDS did. It is a written procedure of vw/audi, you do not need to worry. you won’t damage anything
this is usless since only after 20.000km it will be the same. it is design flaw, when manufacturer dont care about consumer and just make engine euro5 compliant. introducing oily blow by gases via crankshaft ventilation plus sooty exhaust gases via egr both meet in the intake manifold and there is a receipe for clogging everything. only solution is to install egr delete or catch can. newer engines are better since they get exhaust gases after dpf so there are no soot.
I got scared when you did this. I will spray multi spray there every morning for a week, it will be more resistant to different temperatures than WD40. The day I will disassemble it, I will drop brake fluid there in the morning, then I will heat the mortar, it will need to be 90 degrees, I plan to disassemble it that way, I hope I don't break it, otherwise I won't be able to re-make teeth like you.
🔧 Tools used:
🔹BGS 2292 General rachet and socket set: geni.us/0Hhd (Amazon)
🔹BGS 5188 Torx and Hex socket set: geni.us/Zz55Akr (Amazon)
🔹BGS 9473 combination spanner set: geni.us/pxBAWw (Amazon)
🔹Underhood LED light: geni.us/oUVLUpn (Amazon)
🔹Hazet 1979N-92 flashlight: geni.us/gTxEiHA (Amazon)
🔹Hazet 1979WP-1 magnetic charging pad: geni.us/abMfAS (Amazon)
🔹Hose clamp pliers: geni.us/HXeWy (Amazon)
🔹Stem seal pliers: geni.us/67FRPtR (Amazon)
🔹Mirror tool: geni.us/Rtt5v (Amazon)
🔹Thread repair kit M10x1.0: geni.us/HKg2NPf (Amazon)
🔹Thread tapper M10x1.0: geni.us/xJjCREJ (Amazon)
🔹BGS 1981 thread tap wrench: geni.us/67mg (Amazon)
🔹Bendable magnet: geni.us/jxBAi (Amazon)
🔹Gedore 10-50 Nm torque wrench: geni.us/LBhSQA (Amazon)
🔹Wallnut blasting device: geni.us/UvRA0j (Amazon)
🔹BGS 1105 Hollow socket set: geni.us/Ada0LA (Amazon)
⚙ Spare parts used:
🔹Glow plug BERU GE133 geni.us/Zz55Akr (Amazon)
🔹Throttle valve gasket ELRING 006.070: geni.us/TlIW (Amazon)
🔹Manifold gasket ELRING 236.320: geni.us/okjVgCZ (Amazon)
🔹EGR pipe gasket ELRING 214.500: geni.us/4M9uC (Amazon)
⚙ Additional stuff:
🔹Nitrile heavy duty gloves GRIPPAZ: geni.us/tc4XaYP (Amazon)
🔹Brake cleaner: geni.us/LOeBEc (Amazon)
🔹Oil absorbent pads: geni.us/AAvW0We (Amazon)
🔹3M scotch brite: geni.us/zpMfCdQ (Amazon)
🔹Glow plug grease: geni.us/5LxJt (Amazon)
🔹Wallnut media for blasting: geni.us/wW09t (Amazon)
When replacing the egr pipe back into the manifold intake which way does the piece with the hole in go . Does it face towards the engine or does the hole face the throttle body .
@@brendonions1634 According to Intake manifold assembly overview schematic the hole should look towards the engine.
Great work. Will be attempting this myself soon on my b7. Just replaced glow plugs but am almost certain it needs manifold cleaned. Thank you for this. 👏
damn man that would be a nightmare for me, your expertise had saved the engine, congratulations
We were expecting that and its happened :) Had to buy helicoil kit right away.
properly executed repair and well-filmed video! hats off to you! I would have tried to take out the glow plugs with the engine still warm cuz then it is easier but I don't know if you did that so I'm just saying
Good point! I was thinking of heating the block using the heat gun before the repairs, but completeley forgot about it :-) Worth a try!
After cleaning just disable the EGR ore use a simulator. Bleeding with a tester is stricly necessary as otherwise the CP4 pump will die soon or after.
Excellent video, will be tackling this soon myself. Thanks for the part numbers!
Guys allways unscrew glow plugs when car is super hot its less likely to break. Thank me later😉
How do you do this when it takes an hour or more to get all the crap off to even access them?
@@stuartshellenberger9225 You don't need to take the intake off to get the glow plugs out, it's just easier.
Removed my manifold on same engine 2.0 tdi 170bhp cega engine.
After refitting and vcds fuel priming it just wouldn’t not fire and no fuel pressure. Even with a vac pump on return lines we still couldn’t get fuel…..
I’ve got to swap in-line electric fuel pump next week and now dreading it.
Спасибо огромное за видео!
У самого sharan с 2.0 TDI 110kw с пробегом ~220000. Руки прям и чешутся посмотреть что насобиралось во впуске.
Будет примерно тоже самое. Удачного ремонта!
How would you remove the glow plugs if you had to do the job again? Could you remove the top off the glow plug, and introduce a cold fluid to shrink it a bit (eg a compressed gas)?
Also, running the low pressure pump will prime the high pressure lines?
Hi. Hard to say about the cooling, need to test this method. But I would definately heat the engine block with my heat gun next time.
great job , skill and patience
One question: Did you purge the high pressure diesel line using Vagcom alone? Isn't it necessary to loosen the tubes that go to the injectors and then tighten them when they release air? This is the part that I have the most doubts about, because if a lot of air enters the system it is very difficult to remove it. Thanks for the video, very well explained.
Yep. Only with vag com.
egr valves are a nightmare.. had same process done on my corsa.. btw some people from australia use the spray for oven cleaning and it had excellent results with the soot. i will try it with a kamiq when they day comes to do this work
Good to know! Oven cleaner is doing magic, just cleaned my engine pistons recently. Good stuff.
@@dionich Don't use oven cleaner on sealing surfaces on aluminium, it will corrode the surface because oven cleaner's alkaline. It doesn't remove a lot of aluminium but it's enough to destroy valve seats in the cylinder head. No problem using it on steel and probably ok on plastic intake parts.
Great video. Thanks.
I have seen in other mechanics videos, to prevent the glow plugs from breaking, WD40 is used and left to act for an hour, the block is heated with a heat gun and when unscrewing, the spark plug is cooled with gas, either a CO2 cartridge or any other spray that cools it quickly.
Then when assembling it, I ask: Would a small layer of copper grease be good to prevent it from sealing again?
We did forget the heating indeed. This could have helped. Not sure about the copper. We used glow plug paste on the thread, probably this should be enough.
Well worth watching this very informative video.Brilliant spanner work &video.Have removed & cleaned throttle body & egr to get my engine to run decent .Next job inlet manifold to completely DECOKE all the crazy gunge Sh-t....👍.
Definitely a great video, very informative!... I'm actually gonna need the same exact helicoil size you're using for the glow plug repair I'm doing... Thanks for the recommendation brother!!!🤟
Have fun with the repairs :)
Very good work.
Did this happen due to faulty egr valve or its common by 75000 kms above vehicles?
Also recommended to get engine intake valve cleaned ?
Thanks. This is a standart operation of egr system - to shit up your intake. Cleaned my e91 320d years ago, same story. Its better to clean the valves as well in the engine head, this will smoothen the airflow.
Mine have 310000kms and is half of the dirt this guy had. It all depends whats the ridding. Best is long trips.
Greeting. First, let me praise the great effort and detailing. Well done, really!
I have one question - I have a passat b7 2.0TDI 125kw 4 motion, engine tag CFGB.
Belt replacement was done, with all spanners and tensioners, water pump and line belt.
After that, the car consumes at least 2-3 liters more.
Is it necessary to synchronize the high pressure pump together with the intake cam? Because I'm afraid that the mechanic didn't do the synchronization, because he didn't use locking tools (for crankshaft, cam and pump). He just marked the crankshaft with a marker...
Hi, thanks.
We are about to do this job in the coming months. As far as I remember from the manual, the fuel pump needs to be also locked with a special locking pin. Cannot suggest whether the pump should be synced or not, I don't know the mechanics of those fuel pumps. It could be also that your mechanic lost the proper ignition timing whilst not using locking tools.
@@dionich thanks for your reply!
the car starts quickly, just like before changing the belt, only the consumption is higher by 2-3L.
before he was spending about 7-8L in the city, and now it goes over 10-11L.
so I'm afraid that something is not synchronized properly.
@@radulepghi man, we have the same story and I'm thinking to do a timing belt adjustment with hp, my mechanic man told it doesn't matter to time the hp pump but i think i have a high mileage with black smoke, any suggestions about your story?
@@aveirozinou2919 I haven't touched anything on my car yet.
I left it as is.
I don't have a problem with morning ignition, so I didn't work on it.
I don't have any black smoke, the car runs as it should.
Except that, a little higher consumption.
Check injector parameters, through diagnostics, to be sure that the problem is not with them.
Basically, everything should be in sync, because that's how the factory made it.
But I'm not sure if your black smoke is from an unsynchronized pump.
How does the car work on idle?
Is it shaking?
@@radulepg no shaking no hesitating, car works fine even when you rev the car answer fast, but i think the way my car start is different from before i changed the belt, black smoke is before and after i changed the belt, but with high mileage consumption than before, so my question is does a timing belt adjustment for hp is required or not
I've got a 2013 with 112k miles on it, should I do this at some point in the near future?
You can start preparing for this job. I did several previous diesel cars with 240-260k kilometers including this passat. They looked the same, all clogged with soot.
they get like this after only 20.000km. my is same and i dont clean it since it is pointless and car works fine
I'm gonna spray seafoam into intake pipe at 2500 rpm. Then after 10000 km do it again egr delete at 200 km I'm at 370 km now but I looked into the throttle body and it only had the tiny amount of oil on the lip. Very clean and never cleaned before. TDI 2012 jetta
I changed the intake manifold on my audi a3 2.0 tdi, but now it doesnt start. Do you know what’s the issue?
@@kristianlind9977 Maybe some sensors are not connected. Check the fault codes and all the connector plugs.
Try bleeding the fuel system then you should be good to go
A well done job. Perfect
How long did it take you/does it take to do this whole process?
Few days if all go well. 3 days if you will have issues with glow plugs.
where do all the metal filings go when you drill that hole out ?
The hole is plugged with an old glow plug
@@dionich , surely metal filings will get wedged around the old plug and cant get sucked out, when you do vacuum around that old plug its not going to be able to such it all out.
I cant believe that no metal filings will fall in with this process.
Additionally at this point its the right hand plug hole:
ua-cam.com/video/sTn4KLAf-vk/v-deo.html
Then at this point in your youtbe you are dropping it into the left hand hole ?????
ua-cam.com/video/sTn4KLAf-vk/v-deo.html
You have egr - you have jammed monifold and most other engine problems. No EGR - no problem and engine will get fresh air like it should be.
hey nice Vid the only thing that triggered me was how you used the torque wrench 😬😅
Thanks. Thats my father in law, never trusts a torque wrench :)
Hello, i have the same engine and I'm suffering from black smoke when accelerate from idle to an rmp number (so that happen when you accelerate not when you hold the rpm), i chekcked timing belt its okay, i added injector cleaner and checked injection timing by vcds all okay, new filters of course, changed maf sensor and i still have the same problem, i also cleaned egr and catalytic converter, any help!?
Hey. Black smoke is mostly due to rich mixture. Intake air filter clogged or injectors leaking. Check the intake hoses, manifold with smoke test as well.
@@dionich thank you for the reply, all filters are new, maybe intake manifold leaking i will go for it, please tell me do i have to check the timing of the hp fuel pump or it doesn't matter
@@aveirozinou2919 Not sure wheter hp pump timing is essential, although we are going to replace the timing belt ourselves in September and I remember according manual that hp pump needs to be locked with a pin as well as the camshaft.
@@dionich i will do a second timing belt adjustment with hp of course and i will update my result, thank you
How much walnut granulate did you need?
Maybe 1-2kg
anyone know how to prime the fuel pump without vcds?
Find the fuel pump and fire it up using 12v
@@dionich thank you for fast reply. i turned the key to contact a few times, and cranked it 3 times for about 5 seconds and it turned on on the 4th try. definitely wouldn't recommend though. my car is a 2012 audi a3 8p 1.6 tdi. about 5 hours of work including good cleaning i followed your tutorial and my car works like charm now, thank you very much..
Hi what symptoms will this cause thanks
Hi. Slight loss of power, increased fuel consumption.
@@dionich thanks
Do I really need the VCDS tester, or will the system bleed itself if started long enough?
Theoretically should bleed :) But the lines could get aired
@@dionich From all I have read meanwhile, the injectors could get damaged if they run too long without diesel. Too risky...
@@KarlNapp429 I had the scan tool from the beginning, so hard to tell the outcome of doing shortcuts :) I would better stick to the proper procedure
no need VCDS or any other OBDII tool for this procedure. Just turn 5x the key in position for about 10 secs. Pump will do the same as VCDS did. It is a written procedure of vw/audi, you do not need to worry. you won’t damage anything
@@dovaladthanks for advice
How many miles?
250.000km
Thank You very much! 👌🏽👍🏽
Nice chance to replace thermostat with inlet off.
Could u tell me the direction of the egr feed pipe? Hole towards inlet or opposite?
From the block towards the intake manifold
@@dionich thanks but, the egr pipe has a hole once inside the manifold what direction should that hole be. Hope you understand this question
@@Super-lucky-7777 Hole is at the manifold side. In the block side theres a flange with a metal gasket. Is this ehat you need?
Grazie👍🏻💯💪🏻🙏
How much would you charge for this repairs on Audi Q5? You want to trade it for vacation in Croatia (Town on the sea) 😛
Hey. Good offer ;) But I don't repair non-family cars
Gal uzsiemi tuo?
Ne
nice video very useful
Wow good job ❤
Thank you! Cheers!
😀🤦🏽♂️ can I bring my Car over for maintenance?!
Yep ;-)
@@dionich Adresas koks?
Tai buvo mano kolega, siap neremontuoju masinu ;-)
this is usless since only after 20.000km it will be the same. it is design flaw, when manufacturer dont care about consumer and just make engine euro5 compliant. introducing oily blow by gases via crankshaft ventilation plus sooty exhaust gases via egr both meet in the intake manifold and there is a receipe for clogging everything.
only solution is to install egr delete or catch can.
newer engines are better since they get exhaust gases after dpf so there are no soot.
Modern eco reality.
Easy was is to defeat the EGR system so no future issues.
👏🏻👏🏻
I got scared when you did this. I will spray multi spray there every morning for a week, it will be more resistant to different temperatures than WD40. The day I will disassemble it, I will drop brake fluid there in the morning, then I will heat the mortar, it will need to be 90 degrees, I plan to disassemble it that way, I hope I don't break it, otherwise I won't be able to re-make teeth like you.
Good luck mate!
Should be using penetrating fluid like PB Blaster or KROIL. WD40 is garbage and doesn't do anything for this kind of procedure.
you fuck whith glow plug ! u need first heating engine then trying to unscrew it
This looks like a pain in the arse
It is indeed