Audi A6 2.7 & 3.0 TDi EGR & Intake system cleaning info please...

[Columbusracing]

i've left a little something in that thread will be back in to check how it went down tomorrow lol cheers gup hope to see you soon fella

[Scott K]

Great job and good idea doing it on a spare part. To be honest, I'm a bit afraid to check mine!!

[gupsterg]

Yesterday I was searching around for swirl manifolds, whilst doing google images searches I got hits to other forums ...

This guy suffered the same EGR inlet blockage as I did on the throttle body adapter Link:- ImageShack® - Online Photo and Video Hosting

Here is thread of that person cleaning his top intake section Link:- Tuto nettoyage admission air / EGR - A6 C6 / A6L C6 / allroad C6 - Forums Audi-Passion / La Communauté des Quatre Anneaux

Here is his thread on creating a EGR flow reducing plate Link:- test modif EGR A6 V6 - A6 C6 / A6L C6 / allroad C6 - Forums Audi-Passion / La Communauté des Quatre Anneaux

As far as I'm understanding the poster is not getting a MIL from doing this or had any ECU mod done ...

Besides the French the Spanish are also at it Link:- Brico desmontaje EGR y admision - Audi A6 / Allroad C6 (2005 - 2011) - Audisport Iberica

Images in post 5 where similar to my manifolds but post 60 are very close to same level of coking Link:- Brico desmontaje EGR y admision - Página 4 - Audi A6 / Allroad C6 (2005 - 2011) - Audisport Iberica

I was quite amused when I found someone comparing their EGR cooling flap unit to my video on youtube Link:- Brico desmontaje EGR y admision - Página 5 - Audi A6 / Allroad C6 (2005 - 2011) - Audisport Iberica

Besides other stuff in these threads post 27 gave me hope that I maybe able to get at EGR valve without removing lower manifolds/complete EGR unit Link:- Brico desmontaje EGR y admision - Página 2 - Audi A6 / Allroad C6 (2005 - 2011) - Audisport Iberica

I have decided not to do EGR delete just yet, I will make a blanking plate to insert at EGR inlet on throttle body so can connect MAF up to get through MOT.

I'd luv to get a remap with EGR delete but really want my car running well at stock first so this will buy me more time to i) source lower manifolds ii) clean EGR system fully

[gupsterg]

Recently started to tackle the 2nd hand EGR cooler I bought of ebay ...

First blasted it with air compressor set to 8 bar, soot did fly out in puff's ...

Next used foaming oven cleaner, I would leave it to soak for x period before draining and repeating process ...

The channels are not in a U shape in the cooler but after the weld/blue line an empty expanse ...





In above video you will note how water rise from all channels rather than one ...

Water look clean in that video from day 1 of cleaning but even on 2nd day when using a straw to fill cooler with oven cleaner soot/carbon is coming out ...

Today is the 3rd day where I am repeatedly soaking the cooler with oven cleaner then draining and refilling ...

[gupsterg]

Howdy fellow members!
Well just as a quick update a mate from Europe ( a fellow VWAF member ) sent me a great little xmas pressie! some new butterflies and bearings for the the swirl manifolds. SO this means when I do remove swirl manifolds and clean them I don't need to worry about wear on them and can replace them as well as the link arms to the motors.

Thankyou SRT88! You the man my friend! Forgive me for not giving you time as I really have been very busy with offline life.

And soon VWAF'ers there will be coming the full media update on how to clean swirl manifolds/swap out butterflies & bearings/links arms! gupsterg style!

[Mersas32]

Hi guys.,
i am new to this forum...
my car is 3.0 tdi quattro 2005.
do not want to start new tread just but i have the problem!!!
i have followed this all procedure, by the way the man created this post is unbelievable!! So much time to detail and efford !!
so.
disconected fuel rails. 2 rails 4 nutts. Isolated all ends with cling tape.
cleaned everything possible in manifolds was not to bad. Assembled everything and tryed to star the car. Battery was week so got additional supply. started 3 go each go around 2 sec turning. Not to bad.
boom!!! Glow plug light blinking!! Test drive no power. Back home connected it showed p0088 high pressure.
deleted went for a spin ok. Next morning installed charged battery left for work boom light again. Same p0088.
came back home deleted ok. Next day all day ok. Next day morning battery flat. Started with help left house. Drove doing various jobs maybe 6 start stops. Noticed that battery level on mmi stay at around 10 percent- minimum. Noticed after each start it was harder to start even though it produces 13.90 v. Last 6th start after 2 hours day jobs .boom both lights on glow plug and the engine check, back home scanned - p0088 and p3344 dtc status ; short to another valve. Now cant get them cleared.

History. Car bought just before the cleaning 2 days. Was all good. No lights. Cleaned it just because wanted to be sure flaps good order. By the way they are and motors are no loose arms all very tight.

battery : looks new but says on the label charge 6 and 13 marked so i guess its past its warranty 3 year, it could not be that recharge would indicate manufacturing date. Its unipart battery 88ah 720 amps. So : it may be that it is not coded to the car its to week its to old its no good for this car thats why i have these faults. But- when bought even it was week no faults so i do not know if battery to fault. But its drawing 0,68 amps with alarm on and gets battery down every morning. Never got a chance to investigate why alarmed its drawing currect -OT.

cables leads: after reassembly and fault appearance checked everything 5 times now. Lubricated every connector with wd40, no cables loose no bent, no broken ,disconected all sensors while car in operation and engine work changes significantly so i assume they are doing their work. I mean all sensors fuel related.

turbo actuator: i can see its moving and when disconected everything vnt moves freely.

Fuel filter new. But noticed that the fuel gauge was working sporadically, after inserted charged battery it still works fine now, i thought need to take pump out to check strainer regarding p0088 but do not know if this could be...

ANY ideas from all welcome and many thanks in advance.
p.s. Getting vcds tomorrow will post news on that before fault were read with launch diagun.

[gupsterg]

Hi peeps ,

Above post has been taken to new thread Link:- Audi 3.0 tdi Quattro codes p0088 and p3348 after disconnecting fuel rails!!!!!!

Sorry still busy with stuff so not been able to do clean/refurb of manifolds/intake.

But here is an unboxing of butterfly repair kit



Here is video of what occurs to internals of manifold Link:- Audi A5 3.0tdi intake manifold problem - YouTube

Viewers may also find this thread handy to view Link:- Audi V6 TDi 2.7 & 3.0 Inlet Manifold, Swirl Flap Repair Kit.

For any info post or PM peeps .

All the best
Gup

[Ryan_Pestell]

did this ever get finished?

just about to undertake the task myself.

either a full delete or just blanking plates, i would prefer a complete delete with altering the water pipe work from the EGR and leaving the EGR soleniods connected to teh wiring and also to the vacuum system so the ECU thinks there is a still an active EGR system connected.

[gupsterg]

Hi,

I have not yet completed project as another project has taken over my life!

You may find this thread/post handy, Link:- My A6 3.0TDi Avant bit of a rebuild and repair thread.

I wish you the best of luck with this endeavour as IMO these engines are so time consuming and a mare to work on.

ATB
G