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
Hi Tony, I expect that you have learned some valuable lessons at this internship. They're great people and there is a lot of wisdom there.
ReplyDeleteJeff
Hi Jeff, I'm definitely learning a lot. So much I'm not able to take pictures of, usually don't have easy access to camera. Great crew here, and all willing tho share knowledge. We're getting into season for doing genset work with service truck, I'm enjoying it a lot.
DeleteTony, good comment about being thorough when you are cleaning things. It pays to watch the details. Tom
ReplyDeleteTony, just checking in to see how you are doing. Hope things are going ok. Make sure you are posting on your blog. That is how I am going to be grading you. Thanks, Tom
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