Sunday was spent doing this, took 5 hours with a couple of breaks!

Im not mechanicley minded at all but found the mechanic of this job easy for anyone thinking of doing it.

It was very fiddley however and my arms and hands are cut to shreads!

The car now revs alot more freely, managed to get wheel spin in 3rd gear on a flat in the dry!

Def worth doing and when i get the money i will be buying the allard replacement pipe.

Very messy job, what every clothe you wear WILL get oily so be aware!

Also found i got 4 more MPG on my way to work than i normally get, dont no if this is related?

what if the egr valve and what did you do to the manifold, i take it you mean the turbo manifold thingy, wow i'm so technical, not, appologies for the lack of knowledge

What does the Allard replacement pipe do? prices?

What does the Allard replacement pipe do? prices?

It stops the exhaust gases being recirculated....

Allard Motor Company

Chris

It stops the exhaust gases being recirculated....

Allard Motor Company

Chris

Ahh right, throws up a fault code though doesnt it :thumbdwn:

Should help the car run cleaner and stop it getting clogged up however

Good one mate! It's a great feeling to know that the extra oomph is all 'cos of your hard work.

Not surprising given the amount of hard work involved - I've heard that VW techs apparently just change the manifold, never clean it....

Good one mate! It's a great feeling to know that the extra oomph is all 'cos of your hard work.

Not surprising given the amount of hard work involved - I've heard that VW techs apparently just change the manifold, never clean it....

I dont bloody blame them! The manifold came off ok, but the EGR valve was a ******* to get back on!

Iv also notice that i seem to have a bit of a V tech effect as well now for some reason!

It revs like mad up to 3000 but when it hits 3500 i get another little boost, never happened before that iv noticed. Anyone else noticed anything like that?

Manifold clean is a job for next weekend Don't have to bother with the EGR anymore

Not sure about what sounds like a little spike at 3500, you running standard power or a remap? All could be revealed with a bit of VAG-COM logging I suspect Whereabouts are you?

Steve

Im going to clean mine sometime this week. I was thinking? Rather than replacing the whole pipe with the allard one. Would it be possible to fit a blanking gasket to cover up the hole and just bolt the egr pipe back over it on to the manifold? That way it would stop the gases getting through and the egr would still be attached? Or is there a sensor in the egr to sense what gases are going through it?

Been thinking of doing this recently myself. I'm sure after 64Kmiles their will be loads of crap in there.

What do you need to clean it?

I was just going to use some carb cleaner and wire wool to do the pipe.

However.....:( I have just checked the EGR and there is oil from the pin hole on the side. I guess that means my EGR is faulty? Though im still seeing 52 mpg and no flat spots? How much are they to replace?

I think a new EGR is about £150.

Been thinking of doing this recently myself. I'm sure after 64Kmiles their will be loads of crap in there.

What do you need to clean it?

old clothes

a 6mm or 7mm (cant remember which ) to remove the inlet manifold

a new gastket for the inlet manifold

a new set of bolts for inlet manifold

some strong degreaser, if wardy is about he knows which stuff i mean the very potent stuff holts??

and some rubber gloves

I wouldnt normally replace the inlet manifold bolts, in fact I dont think I ever have, why do you need to?

where is this egr valve then lol how do you clean that ?

I wouldnt normally replace the inlet manifold bolts, in fact I dont think I ever have, why do you need to?

The ones i reomved were pretty rusted, for the cost of em i thought why not

some strong degreaser, if wardy is about he knows which stuff i mean the very potent stuff holts??

and some rubber gloves

Gave me a cracking headache that did! Remember buying two kinds, was it the Wynn's stuff from Halfords that was best? The canister that sounded like a welder!

Anyway, came up pretty well in the end but did require some fairly serious elbow grease and numerous applications.

Steve

Anyone know the price of a new Inlet manifold?

Word to the wise mate- just clean the old one - bit of elbow grease and its as good as new. Bit of careful dremmeling and it's better than new (gasket matching)....

Bas

old clothes

a 6mm or 7mm (cant remember which ) to remove the inlet manifold

a new gastket for the inlet manifold

a new set of bolts for inlet manifold

some strong degreaser, if wardy is about he knows which stuff i mean the very potent stuff holts??

and some rubber gloves

Cheers John

Gave me a cracking headache that did! Remember buying two kinds, was it the Wynn's stuff from Halfords that was best? The canister that sounded like a welder!

Anyway, came up pretty well in the end but did require some fairly serious elbow grease and numerous applications.

Steve

Ar yes the wynns carb and injector cleaner

I can confirm this is a long job, in the time it took you clean that manifold and the pipes i had removed the turbo and then re-fitted it

where is this egr valve then lol how do you clean that ?

sorry can anyone help with this please cheers

sorry can anyone help with this please cheers

If you dont know where it is you shouldnt me cleaning it

ha ha very true mate lol

Not sure if you are still interested but I think this procedure is described in pictures on tdiclub.com

Fred's TDI Page. TDIClub.com. VW TDI Enthusiast Community

Has anyone found this procedure fixes warm startup problems?

Thanks,

Andy