VW Intake blockage

One of my projects last week. Owner of 03 VW TDI complained of  lack of performance, and check engine light on. The egr, and egr cooler had previously been cleaned, and the MAF sensor replaced. The customer mentioned the intake had also been cleaned out in attempt to fix the issue. The engine ran better with MAF sensor unplugged(it reverts to default setting in computer I believe), but wouldn't rev or get up to speed anywhere close to how it should've. We decided to check the intake runners, and intake ports in the head, to check for coking blockage.

Intake manifold behind the egr. It looks wet, but is dry.

Ready for intake removal

Soaked intake with solvent during lunch.

This coking was mostly in the elbow between the intake plenum and the runner the the egr bolts to. It was missed by whomever had cleaned the intake previously. There was almost 3/4 of a cup of material blocking air flow. 

After re-assembly the car was test driven, and performed as it should, no hesitation to reving, and drove well.

I learned to be thorough when cleaning parts, as the blockage in the elbow of the intake could easily be missed(as it was by previous technician who performed the procedure), and the problem would not be fixed.

  Week 7: 40hrs

Total: 280hrs

Gen Set Self Oiling

A look at one of the projects I worked on last week. I started removing the self oiling system from a gen set that no longer needs it. We're going to be installing the system on another gen set that is much harder to access frequently. 

Here is the float housing and sight glass for setting up the system. The oil level needs to be a pre determined level in the sight glass, which is the same level in the oil pan(or reservoir if not using the factory oil pan). When the level goes below the set low level, the switch(in next picture) opens a valve and more oil enters the pan. The oiling system also gradually changes oil over the recommended oil change interval.

The small light gray box in the lower left of picture with the hoses entering and exiting it is the switch for the oiling system.

The mounting bracket for the float housing.

The power for the switch is the orange lead coming from spot 7 on the green terminal block.

I learned how an oiling system works, at least how this one works, and how to disassemble it. I hope this will make installing the system on another gen set less confusing.

5th week total: 40hrs

total: 200 hrs