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Discussion Starter · #1 ·
Hey,

My car has been suffering from the following:

  • Misfiring feeling on tickover, can feel it in your seat base giving a little shock though the car every 5 seconds or so.
  • Being jerky in slow moving traffic on and off the power, bit like kangarooing.
  • Stuttering when slowly decelerating, say on the motorway at 60 and gently slowing down, then on the power again it'll freeze for half a second and then pick up.
  • It also occasionally gets a shuddering in top at around 60 when under heavy load and hard acceleration - although this I'm sure is attributed to the crappy clasp on the bottom kerbside intercooler hose which is next on my hit-list.... it's smoking a bit more than it should too, again consitent with the hose leaking.

Now happily - all of the above are gone!! woohoo!! the car is running better than ever and I know once the intercooler hose is sorted, it'll be as good as new - if not better.

Anyhoo - check out the filth in the EGR valve. As you can see from the front view (in terms of airflow) that it doesn't seem that bad...

Posted Image


But - looking at the rear, you'll see the diameter available for airflow has been reduced by approx. 30% and the valve is absolutely rotten with carbon.. hense it failing.

Posted Image


Well - ?135 for the part lighter I can say I'd rather have not had to replace it, but 50k's worth of miles and you've got to expect it I suppose? If you're suffering from any problems similar to those above, then I think it is well worth taking the valve off and having a good look at it (get a gasket from the stealers first), I wouldn't know if it was possible to clean it properly - my specialist had a go at it, but it lasted a week or so before it started playing up again.... you've just got to regard it as a wear and tear part.

Can this be edited into the common faults thread/sticky please?

Mike.
 

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Discussion Starter · #3 ·
Really Mickey, I didn't think you could sucessfully do that on a PD?? obviously so if you have!

What issues does this throw up with yours, error codes? smoke? anything?
 

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Ooo-err,

Didn't think we suffered this over here with our cleaner diesel, I know the US suffers it as they've got really bad fuel.

Question ? Is it fixed via an 'o' ring or gasket, might whip mine off to check it ? Mine has always looked clean when I've had a peek at it.
 

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Discussion Starter · #5 ·
Disgusting, isn't it!!!

I was billed for a gasket, so you might want to get one from the stealers first before taking it apart? I'll edit my post accordingly..
 

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Glad you've got that sorted. My EGR is coming off next week so we can weld the first section of aluminium IC piping onto it (the connection just leaks boost and this seems the best solution [:mad:])

I've bought new bolts, but if you have a part number for the gasket I would be grateful.
 

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Discussion Starter · #7 ·
Glad you've got that sorted. My EGR is coming off next week so we can weld the first section of aluminium IC piping onto it (the connection just leaks boost and this seems the best solution [:mad:])

I've bought new bolts, but if you have a part number for the gasket I would be grateful.
I'll get my mitts on the part no. and let you know. Is yours running higher PSI than a normal chipped 150?

It's got me wondering, if that was so clogged up with crap then what is the rest of the system going to be like?.. think a weekend's stripping and cleaning is in order.
 

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Thanks

Ever so slightly. About 1.8 bar at the moment. The connection was never the best. I have had a replica of the EGR pipe connection made in aluminium, welded to the aluminium intercooler pipework. It won't stay put and the boost is flipping the o-ring in its groove, causing boost leaks. As Withnail said, "The F***** willrue the day" as it's being TIG-welded up to the first section of IC pipe. [:D]
 

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Has that got like that in the couple of weeks since it was last cleaned? wonder what the inlet manifold is like too....

Damn stupid idea the EGR valve IMO.
 

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Discussion Starter · #10 ·
"EGR - you really are a terrible c***!"

I'd love to have a good nosey at your car one day James - you going to that RR day near Silverstone?

Gaz - he did say he's only had a quick bash at cleaning the 'in' side of the valve because he didn't have a gasket to replace the old one with when removing it all, that's why the muck differs side to side.

What on earth do you clean the rest with?? carb cleaner could be a bit dodgy on the inlet manifold??
 

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I've put a can of power boost spray through mine about an hour ago, thats supposed to clean things up; however looking at that its not gonna touch that level of fouling.

I expect the intercooler and pipes would benifit, but the EGR and inlet manifold, being warm/hot at that area of the engine get in worse and would need to be taken off.

Have you looked into blocking the feed off the exhaust to stop the soot and crap being allowed back in to cause this? I've been told you can near disable it by VAG-COM or block it with a piece of metal over the end of the pipe with no major ill effects....

....just a pity to put another on and allow it to slowly coke up again.
 

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Discussion Starter · #12 ·
I did see a 'how to' on TDIClub for cleaning the intercooler - might be worth a crack?.. but I'm deffo going to strip and clean as much as I possibly can, it's all bound to be in some sort of coked up state.

See what you can find out about this blocking technique and if someone has a VAG-COM on Sunday we can have a play with it to see what happens.
 

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Really Mickey, I didn't think you could sucessfully do that on a PD?? obviously so if you have!

What issues does this throw up with yours, error codes? smoke? anything?
No error codes or nothing, as the solenoid is still connected
 

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Think i best get my car booked for its 4th annual service and arrange for a specialist to do some work on it..

its not been too smooth lately and the AC fans need sorting.

Tempted to just sell... shame can't afford ?10k for a decent replacement really.

Even tempted to replace with a Suzuki Swift... should be more reliable in the long run.

anyhow, thanks for the info, I shall get my valve checked.
 

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Discussion Starter · #15 ·
Ahh don't be disheartened, a couple of common faults sorted out and you'll be right as rain.

Another car might be more reliable, but they'll depreciate like a rotting peach and you'll lose more than it would have cost you to put the Bora right in the first place. Most of this stuff you can tackle yourself - I'm just a bit lazy at times and my local guy at Votex is so good it's unreal!

Get your EGR valve off and have a look at it, I'm going to have a crack at cleaning my old one to see if it is successful - I've nothing to lose. Get it cleaned and check the hoses for slippage/leaks (oil traces on the undertray as you look at it from the nearside wheel is an indicator) and unless you're really, really unlucky and you've got one of the dodgy flywheels you should have everything fixed.
 

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Tony, Thanks for the post - it is this sort of info that allows people like me to continue running our cars. I understand how the previous poster feels as I sometimes feel the same - I run a PD115 on limited funds but I,ve just been reading the posts about the number of head gasket failures on this model and much as I love my car I,ve been wondering whether it is time to cut my losses. I bought the Mk4 after running a MK2 GTI for 14 years and I expected the same sort of reliability from the Mk4. The reality has been very different and I have had far more problems in 2 years than I had in the previous 14 - also the problems on the Mk4 tend to be major and very expensive to fix.

As I love the car I,ll probably persevere and hope for the best but without the info on this forum to help me fix problems I would also be heading down to the nearest Suzuki dealer as I,m pretty fed up with the dealer attitude and poor build quality of current VWs.
 

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I did see a 'how to' on TDIClub for cleaning the intercooler - might be worth a crack?.. but I'm deffo going to strip and clean as much as I possibly can, it's all bound to be in some sort of coked up state.

See what you can find out about this blocking technique and if someone has a VAG-COM on Sunday we can have a play with it to see what happens.
No problem. How's Tom geting on with his?
 

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Discussion Starter · #18 ·
I did see a 'how to' on TDIClub for cleaning the intercooler - might be worth a crack?.. but I'm deffo going to strip and clean as much as I possibly can, it's all bound to be in some sort of coked up state.

See what you can find out about this blocking technique and if someone has a VAG-COM on Sunday we can have a play with it to see what happens.
No problem. How's Tom geting on with his?
Not sure, I don't think he's on the best of terms with Listers though!!
 

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Discussion Starter · #19 ·
Tony, Thanks for the post - it is this sort of info that allows people like me to continue running our cars. I understand how the previous poster feels as I sometimes feel the same - I run a PD115 on limited funds but I,ve just been reading the posts about the number of head gasket failures on this model and much as I love my car I,ve been wondering whether it is time to cut my losses. I bought the Mk4 after running a MK2 GTI for 14 years and I expected the same sort of reliability from the Mk4. The reality has been very different and I have had far more problems in 2 years than I had in the previous 14 - also the problems on the Mk4 tend to be major and very expensive to fix.

As I love the car I,ll probably persevere and hope for the best but without the info on this forum to help me fix problems I would also be heading down to the nearest Suzuki dealer as I,m pretty fed up with the dealer attitude and poor build quality of current VWs.
No worries, I know it's hard not to kick the doors in when something expensive goes wrong and want to cash in your chips for a mundanemobile.. I used to have a MKII on a showstring and it broke my heart when I fell foul of the old crap in the oil pump strainer and it bombed the bottom end - I repaired it and got a work's Astra diesel instead as I'd just had enough. As much money as I saved, and to be fair it was faultless I just had to get another VAG.

There's loads of people on here who are more than willing to help others out and there must be a 'how to' for everything imagineable - so don't give in just yet!
 

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I checked mine last summer and it was clean with only a light coating of black oily gunk....no where near as bad as those pics!

I would really like to clean my inlet manifold though, I just can't seem to find a guide on doing it. The one on TDI Club is for the non PD TDI.

Glad you got it sorted though Mike [Y].
 
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