Intake Manifold Cleaning And EGR Removing Carbon VOLKSWAGEN GOLF 2.0L TDI 2006~ BKD 02E 6S DSG

[@ivstefanov]

he sprayed all the dust and garbage into the cylinder head, great job!

[@PropanePete]

Just came across this video, I have the same BKD 2.0 ltr TDI engine in my Mk5 Golf. It's gunked up and I'll be doing this job myself pretty soon. I'm a former mechanic from decades ago and I definitely will not be spraying any solvents or anything at all into the intake ports. Some of the valves will be open and you don't want corrosive solvents getting on the cylinder walls, or working its way down to the piston rings. I think he used oven cleaner for the manifold, EGR and cooler, etc, but didn't see a new intake manifold gasket go on. However, it looks like he's achieved a pretty good result but I'm uneasy about using oven cleaner on engine parts when there are specific solvents available for jobs like this.

[@richcheema]

Hi. I'm going to be removing my intake manifold this week for cleaning. I have an aluminium one similar to that in this video (2009 Mk6 Golf with CBDC engine code). You mentioned he did not seem to change any manifold gasket and I picked up on this too. All I see online are elastomer gaskets and I think they are for plastic manifolds. Do you know if one is required? Or is metal to metal seating sufficient to stop leaks on these metal manifolds. Can't seem to find much online

[@PropanePete]

@@richcheema In my experience as a former mechanic metal to metal seating never seals. Your alloy Mk6 intake manifold will definitely not seal properly against the head without a gasket and you will get a vacuum leak. Go online to a parts distributor and you will see that there will be a gasket listed for it. My Mk5 BKD has a conventional inlet manifold gasket. There is nearly always a bit of distortion or warping in two metal surfaces that are to be mated. Gaskets take up these irregularities and provide a seal. There are some amazing gaskets around these days, particularly with plastic parts and some gaskets are reusable. Always check the workshop manual. Incidentally, oven cleaner has sodium hydroxide in it which corrodes aluminum and alloys so use something else to clean the intake manifold. Maybe a flexible rotary wire brush that fits into a drill chuck, that will do the job nicely without chemicals.

[@richcheema]

@@PropanePete Thank you for all the advice. I spent most of last night looking and I've found the part number for the correct gasket. I'll heed your advice on the oven cleaner too, I might just scrap most off and use naphthalene and brake cleaner to cut through anything left over.

[@PropanePete]

@@richcheema You don't really need any chemicals to clean out the inlet manifold once you've removed it and got it up on your workbench. Any decent tool store will stock flexible wire brushes. These are a flexible multi strand wire shaft of about 25 to 30cm length with a round wire brush on one end and a metal crimp on the other. You simply put it in your drill and move it up and down, back and forth in the inlet manifold and it will remove all the built up gunk. You can finish off with brake cleaner if you like, good stuff, doesn't hurt anything. Make sure you scrape off any remains of the old inlet manifold gasket before putting the new one on. You'll need a 1/2" drive 6mm hex socket and short extension for the inlet manifold bolts and the EGR valve will need to go on last as it shields access to a couple of the lower inlet manifold bolts. Torque is I think 25Nm if you have a TQ wrench, otherwise just common sense tightness. Tighten in steps starting from the middle and radiate outwards. There's nothing much you can do about gunk buildup around the inlet valves without removing the head and stripping it down. That's a big job but at least the EGR valve and inlet manifold will be clear of buildup. Don't try and chip away at buildup on the valves through the ports with a screwdriver or anything, you can do damage.

[@Choober65]

Oven cleaner work well to unclog turbos when the vanes stick. Sure it kills the cat and dpf, but at over £400 for a new turbo, who cares?

[@MrColalaco]

VW dealer just quote me 5 hours for replacing an EGR. total cost including labour and Vat 1360.00 pounds. This man just did under half an hour or so. amazing!

[@raivedarkstone7378]

He's talking shit, I've literally just come in from taking mine off, i'm a novice and it took me an hour (without manual), they are literally bolt off bolt on, when you pop the bonnet they are RIGHT there in front of you, if a mechanic is taking 5 hours to do this he needs to be retrained, sounds like he was including a few hours testing and all, still a total ripoff, the cars these go in are seldom worth the prices they charge, can get a new EGR on ebay for between 50 to 90 quid!

[@Choober65]

Just took me three hours to remove an egr valve but as I've never done it before not bad I think.

[@EnglandsVoice]

I Wish it was you doing mine right now, I'm sure mine won't be done that easy well quick ,

[@ashab87]

Were all the valves closed when u sprayed that stuff into the head? What did u use?

[@Liveforeever]

They obviously weren't because he sprayed all the ports without turning the engine to close the valves. It probably was a solvent cleaner so would have evaporated by the time he started the engine

[@olindor220]

@@Liveforeever The solvent shouldn’t be a problem, it will evaporate before he put all together My concern is that all the deposits have been pushed inside the cylinders and the carbon deposits are abrasive and can cause scratches on the cylinder walls

[@nasratnasrat1195]

Wow, this is a very cool job, I have the same car and you need this wonderful work Is it possible to write down the type of spray used for cleaning

[@smokeyjoe4248]

Is it safe to squirt cleaner into them holes of is it fine?

[@user-GTK9]

how many kilometers has the engine?

[@Dadobn]

What type of foam you used???

[@LunguCosminGeonica]

hello, i am the owner of a vw golf 5 2.0 tdi and I have a problem with the coolant, there is leakage between the engine and the gas cooler, there is the possibility that this gas cooler has cracks and need to be replaced or the fault are some gaskets of this cooler that can be replaced?

[@navisolim]

gas cooler or oil cooler? what is a gas cooler anyway?

[@LunguCosminGeonica]

@@navisolim exaust gas recirculation, the one behind the engine in this video

[@aleksandrasbezenar7353]

I suggest you simply just deleting the egr cooler.. Here's a tutorial for it www.mk5golfgti.co.uk/forum/index.php?topic=72241.0 Or you can check all the rubber hoses, maybe one of them has a crack and it's leaking coolant out

[@Benko_DieseL]

is this the same procedure for 170 bmr engine?

[@TheBigwill104]

what type of foam was sprayed in the internals

[@Gu1ll3rmOx]

Carburator Cleaner maybe

[@dennispowers7261]

@@Gu1ll3rmOx oven cleaner..

[@Ceaz000]

Thank you. 👍👍

[@shadowboybass]

what is that product ? for decarb...

[@mkatalin09]

They foam used in this video is not oven cleaner like many of you say it is designed for carb and choke removal like it says on the bottle the fact that he sprayed the solvent in the engine with some of the valves open.........now thats a shitty thing to do.

[@redxxredxx1731]

Nice thank you for the video!

[@Freddie1980]

Are you sure that's an 2006 Golf TDI? I have a the same model but my engine bay has the intake manifold and EGR valve at the back or the engine bay.

[@dopiaza2006]

Yours is probably a 1.9

[@raivedarkstone7378]

I've got a 2006 2.0 jetta TDI, that's what engine he was working on, i've heard lots of people saying they've bought 2.0's but really it's a 1.9 PD

[@lambokid20]

Glad I found this video, installing a boost gauge on my 2.0tdi into the manifold and jus. Found the best way to remove it through this video, thank you !

[@westnotes1971]

thank you.perfect work.

[@jettmekhi8083]

I realize it's kinda off topic but does anybody know a good website to stream newly released movies online?

[@bradenkohen1014]

@Jett Mekhi I watch on flixzone. Just google for it =)

[@Choober65]

BKD is an oil burning POS. I have a 1.9 ALH in an earlier Bora and it is spotless in the intake and intercooler. Runs a million times better than the BKD too.

[@PkmHax]

What was that you took out of the back of the engine? Im confused haha. Is it necessary?

[@sinaniii]

Andy X probably the EGR cooler

[@robertkakumba7230]

Took almost 7 hours. That carbon is not easy to remove. Infact it needs to soak overnight to be that clean

[@mrD66M]

I'm doing the intake right now. 2 days of scraping and soak overnight in white spirit - dirtiest job ever

[@robertkakumba7230]

My mechanic said it was not necessary

[@Stoffeangel]

Foam is reallly bad at removing greaseand oiled substance I've yet to see nor I have ever seen any one remove grease with foam it does not penetrate liquid does. Foam will only make the top surface wet and grab it with it when removed but will not penetrate all the way and make it loose for the surface it is attached to.

[@Unicornmeme123]

I disnt get anything from this vydwo

[@gesheepistemology8050]

What the fuck was that very last tool? 20.10/20.22