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Kbell, here are some other pictures I took while cleaning the throttle bodies. here are some steps:
1) remove engine covers all the way around (20ish black pop up clips) and center one just pops off.
2) remove hose clamps on intake hose going into first throttle body (picture one). Then remove the four torx bolts and the sensor wire clip holding the throttle body onto the plastic intake tube. (set aside this throttle body and clean)
3) Next you're going to remove the black plastic intake tube. This involves removing the EGR tube going into the bottom of it (loosen hose clamp with allen key in the pictures below, pull that hose down and away). I believe there was also a torx screw or two holding the intake tube to the engine on amount or two. Look around for those if it doesn't seem to budge.
4) Then you're going to remove these four allen bolts holding the intake to the second throttle body. (plus a sensor wire or two)
I believe there were also bolts holding the second throttle body to the intake, but I did not get pictures of those. The long allen bolts may have held both to the intake, I'm doing this from memory/pictures.
Once you have everything apart, clean the crap out of it with throttle body cleaner and brushes/ towels.
Put it all back the way it came off. Also make sure you have a beer handy.
The latter on the swirl flap to intake manifold. They are long through bolts that go through the charge pipe and swirl flap into the intake manifold. If you are missing any they can be purchased at VW for about $1 each.
No gaskets involved in just this first stage of throttle body cleaning. I’m Starting the bigger project of intake off and EGR cleaning tomorrow. Not sure what gaskets are involved there but I plan to re-use or use a silicone gasket maker if necessary. I’ll let you know what’s involved there.
doing the cleaning ourselves, will it void or harm our extended warranty?
was this also for Gen2?
Is this just a part of owning a diesel or did the fix have something to do with the build up? (I recall that previous GM diesels required cleaning as well but checking).
I’m interested in doing this on our MY15 as part of preventive maintenance (no symptoms).
I attempted the intake removal to get to the EGR valve and clean everything out. I've rebuilt a few engines over the years, but this was by far the worst time I've had on car. After about 6 hours in the garage yesterday trying to free the intake, I had to give up and reassemble, as the wife needed the car today. I was able to remove all torx bolts holding the intake down (no small task), so it was "free" but I have no idea how you freed all the electrical and fuel lines on the back of the intake to allow it to slide out. There are like 4-5 lines running along a black plastic mount that didn't seem feasible to disconnect. I though I may have enough room to just slide it under those but nope. I was stuck and frustrated.
Any advice or tips on how you got the intake actually out of the car? FYI this next step of the carbon cleaning repair is not for the faint of heart.
Car is supposed to go in for service Wednesday. I might just BEG them to do this service.
Do we know what the effect on performance is from this gunk/build up? Acceleration, MPG, and most important...emission.
Would it be be valuable to do an emission test pre and post cleaning? I’ve just had my emission exam , I’d be interested in the results post cleaning (assuming I can get the detail of the results).
Post compression burn/scrubbing should handle any increase due to this build up but several have talked about DPF and/or sensor replacements. Trying to separate normal vs post fix vs original software manipulation.
Should the “cleaning process” described above get its own thread OR DIY?
I attempted the intake removal to get to the EGR valve and clean everything out. I've rebuilt a few engines over the years, but this was by far the worst time I've had on car. After about 6 hours in the garage yesterday trying to free the intake, I had to give up and reassemble, as the wife needed the car today. I was able to remove all torx bolts holding the intake down (no small task), so it was "free" but I have no idea how you freed all the electrical and fuel lines on the back of the intake to allow it to slide out. There are like 4-5 lines running along a black plastic mount that didn't seem feasible to disconnect. I though I may have enough room to just slide it under those but nope. I was stuck and frustrated.
Any advice or tips on how you got the intake actually out of the car? FYI this next step of the carbon cleaning repair is not for the faint of heart.
Car is supposed to go in for service Wednesday. I might just BEG them to do this service.
I didn't go that far. I *want* to, and maybe will *someday* - but haven't yet. I stopped at the two TB's and that intake tube.
I guess your experience explains why book time on a EGR replacement is, IIRC, 8 hours. The intake manifold must be a legit project to R&R.
I took on this project Sunday morning.
2 hours start to finish.
However, I did NOT remove the Manifold.
I just put a flexible vacuum in the manifold.
Everything else, I cleaned with tooth brush.
Very messy black carbon.
YES. Improved performance. More linear acceleration. Decreased turbo lag.
Very pleased.
25,ooo miles post fix.
The wife even noticed a significant improvement.
She was very pleased.
07-24-2019, 04:26 PM
