Author Topic: intake clean!!! (Read 5718 times)

Hammy · « **on:** March 03, 2005, 09:50:37 am »

I took the opportunity last weekend, to do the intake/intercooler clean. What a mess. I couldn't believe an engine could run with the intake practically plugged!

The openning was no larger than a quarter, ha. It took about 3 hours to remove parts and reinstall, but it took 4 hours to clean the sucker (that's what it is, a sucker! :roll: ) I took it for a drive after, and wow! It felt like a 20 horse kick in the pants! The car has 220Kms on it, and it runs like new. If you pin it in first gear it will blow the tires off the rims! :lol: Ok maybe I'm exaggerating a bit here, but you get the picture. Now we will see about the fuel mileage? I flushed out the intercooler too. It was easy. If you have any mechanical ability at all, I would recommend doing this yourself. Saved me $350.

One can of oven cleaner, a tube of RTV sealant, and some rags. I didn't even jack the car up, or remove the belly pan/shield.
Everything was done under the hood, except disconnecting the lower intercooler pipe from the intercooler. The intercooler is flushed out in the car, removal appears to require removal of the bumper to access the upper mounting bolts.
Like I said this was fairly staight forward, and anyone who has some wrenching abilities should do this themselves, and save the money. You don't even need to buy a new intake gasket. Good luck to all.

dieselpower · « **Reply #1 on:** March 12, 2005, 05:00:32 pm »

hey,
on my dads tdi he took the crankcase breather and routed it into a catch can witch he empties everytime he changes the oil. the gunk in the intake is a combination of the soot from the exhaust going through the egr valve and the oil from the crankcase breather. so by elimintaing the crankcase breather from going back into the intake, you basically eliminate the buildup in the intake as well.
just an idea for you.

Mark

Hammy · « **Reply #2 on:** March 12, 2005, 10:44:55 pm »

Thanks for the tip Mark. I have been thinking about that similar idea for a while, also. How big is his catch can, and how much does it accumulate over the time span?

Thanks;

dieselpower · « **Reply #3 on:** March 13, 2005, 11:56:02 am »

hey,
the catch can is about a 1foot peice of 2 inch pvc with fittings on the side. im not sure how much it accumulates but he is getting home from a trip to california today...so i'll check it out and take some pics of it later.

Mark

Hammy · « **Reply #4 on:** March 14, 2005, 08:25:20 pm »

Pic's would b-e greatly appreciated, Mark.
Thanks in advance.

srivett · « **Reply #5 on:** March 15, 2005, 01:27:57 am »

I'd probably fill the can with really coarse steel wool. I believe it helps turn the steam back into oil.

Steve

dieselpower · « **Reply #6 on:** March 15, 2005, 01:54:15 am »

hey,
sorry it took soo long. im not too sure about the steel wool turning it back into oil...but my dad has it in there. anyway its mounted to tight and too many things are hooked up to it so i just drew a pic to go along with the in-car pics. he said it gets between 50-100 cc's of oil on a trip like he just took. from the montana border to the mexican border, however far that is. anyway he has a coolent hose wraped around it to kepp it warm so it flows good in the cold and doesnt get plugged up.

the top hose is just a vent that goes down to the undercarrage of the car. the valve on the bottom also has a hose that goes down to the bottom so he can empty it without taking it out of the car.

if you have any more questions just ask.

Mark

P.S. sorry it took soo long. i couldn't figure out why my pic wasn't working, i guess u can't usp bmp images.

Hammy · « **Reply #7 on:** March 15, 2005, 12:05:49 pm »

Thanks Mark for the great pics. The cannister is made of ABS right? Does he have the intake port (where it used to plumb into) capped off? Does it leave an oily mist on the undercarriage? I would assume not, since it is collected in the cannister with the steel wool. I could see the steel wool helping to separate the oil from the air.

dieselpower · « **Reply #8 on:** March 15, 2005, 06:54:46 pm »

hey,
yes its just 1.5" abs pipe. no its not plugged off. it has a hose going to something in the side covered in duct tape so i dont kno what it is. i'll ask my dad when he gets home. ya it doesnt leave a residue but i'm not saying that it wont leave anything at all. there might be a minute bit that gets past the canister, steel wool, then the hose...but im sure that wont affect anything.

hope this helps

Mark

dieselpower · « **Reply #9 on:** March 15, 2005, 07:10:02 pm »

ok,
the hose goes to a little paper airfilter. because the computer is calibrated for a little bit of air to come through after the maf sensor he just did that to keep it how it should be. it's chipped tho so i dont understand why tho. anyway he said to keep it "legal" the outlet on the canister should be run back into the intake and it would remove about 95% of the problem.

good luck,

Mark

Hammy · « **Reply #10 on:** March 15, 2005, 10:51:31 pm »

Thanks for the great info, Mark.