ALH Intake cleaning

[catlin_cava]

I think my intake is clogged up and I figure its time for a cleaning..

Since i don't have cool fancy tools and remove motor usually involves a sawsall and torchs I'm taking gentel care of my TDI baby.

So How do I clean it?

[Vincent Waldon]

1) You can fritz with it yourself mechanically:

- wooden stick to remove the big chunks
- soak it with your favorite degreaser
- power wash it

2) You can light it on fire red-neck style with a propane torch and compressed air: http://www.youtube.com/watch?v=oet4qWeZuYA

3) You can take it to a machine shop and have them bake it in their oven and then clean it out and bead-blast it.

4) You can find a vendor who will ship you a clean one and then you ship back your dirty core. No down time.  There are a couple on TDIclub.com

I personally use #3... he charges me about 50 bucks... but you may not live near a machinist that has a big oven.  They come out looking like new.

[catlin_cava]

How hard is it to remove? If I break something I'm in hot water because my GF will murder me

[Vincent Waldon]

It's not hard but will take a few hours... here's a good how-to:

http://pics2.tdiclub.com/gwillie/VW/Sballintake/INTAKEMAN101b.htm

Basically you pull off the hoses, all of the EGR stuff, and then unbolt the manifold itself and remove it.

Unfortunately it's gotta come out... a chunk of hard carbon down into the combustion chamber would definably ruin your day... and your GF's.

[the caveman]

We used to clean them by sticking them into a bucket of diesel atf and varsol . OF course it would take a month or two, but we would do it on an exchange basis. We'd clean VNT's that way also, being careful not to dunk the vacuum can in the mix..

[745 turbogreasel]

You can pull the EGR, and hook a scraper back there to see how thick the goo is.
I went with the redneck method followed by rifle brush.
Easy, fun, and effective, but be sure you don't track any of the globs that fly out back into your house.
I reused the EGR gaskets, and they don't leak.
I already had the head off, so R&R was easy.

[lord_verminaard]

I did the torch and compressed air method.  Kinda scary and messy, but fun and it works FAST.  Once it stays lit and gets hot, set aside the torch and add more compressed air and eventually you'll get jet flames about 3' out of the ports.   

After it cooled off, I bead-blasted it real quick and it was spotless.  Be careful though!

Brendan

[745 turbogreasel]

And be sure not to step in any of the splats that fly out,  they are hell on carpet.

[greentdi]

I use A heavy bendable rod about the size of a coat hanger but stiffer scrape most of the gunk out. I made a plate that bolts on where the egr sits. The I fill it up with purple stuff and let it sit over night. Flush it out with water and repeat if needed. If you use purple stuff and let it sit on the exterior of the manifold it will discolor it.
oven cleaner works good too but will also discolor the metal.

[8v-of-fury]

i assume any big name degreaser will really do the trick here.. letting it soak sould really loosen it up and give away the need to be physical with the manifold at all, I would think.

Going to have to be doing this on my AHU soon, Post up what you figure out Catlin

[R.O.R-2.0]

FIRE!!!!

my vote is for the fire method..

whats more fun than fire?!

[lord_verminaard]

i assume any big name degreaser will really do the trick here.. letting it soak sould really loosen it up and give away the need to be physical with the manifold at all, I would think.

I tried that first, just made it more gummy and sticky.  Fire is the fastest/easiest way I suspect.

Brendan