Today I.....

.....filled up with 38 litres of diesel having covered 452 miles, resulting in an improving economy figure of........... 54mpg. Wow ?. I’ll credit that to the warmer weather, remap and an Italian tune up, rather than the 4 wheel alignment, Redex treatment and refitting of the undertray. Still trying to work out whether it’s worth the pain of removing and cleaning of the EGR valve to try to improve that figure.
 
.....filled up with 38 litres of diesel having covered 452 miles, resulting in an improving economy figure of........... 54mpg. Wow . I’ll credit that to the warmer weather, remap and an Italian tune up, rather than the 4 wheel alignment, Redex treatment and refitting of the undertray. Still trying to work out whether it’s worth the pain of removing and cleaning of the EGR valve to try to improve that figure.

Yes it is worth the effort especially if the egr has been or is still active
I have done a few where there was little more than than two1/2” holes


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.....filled up with 38 litres of diesel having covered 452 miles, resulting in an improving economy figure of........... 54mpg. Wow ?. I’ll credit that to the warmer weather, remap and an Italian tune up, rather than the 4 wheel alignment, Redex treatment and refitting of the undertray. Still trying to work out whether it’s worth the pain of removing and cleaning of the EGR valve to try to improve that figure.

As Paul says, you've got to take a look! It's really not that bad. As you know, I took my scuttle trim off as the wiper arm was off anyway, so did the 'air duct removed' method rather than the advanced 'grope around in the dark' method of the experts here.

Tools other than very standard stuff:

Pipe pliers to undo quick-clamps on various hoses.
Small torx (20/25?) for two screws for vent duct hidden under scuttle trim.
6mm allen with short side cut down to about 15mm overall.
5mm allen, longer the better but if standard size just refer to pic on my Break/Bale thread.
If you've got a T30 torx 'screwdriver' that works perfectly to quickly un-wind / loosely wind in the 5mm's.
Old container to wash the thing in. Use gloves!! The gunk basically turns to black ink.
Can carb / throttle body cleaner. Plus a bit of old petrol from the mower for initial cleaning.
If you've got a few lolly sticks for pre-scraping the gunge off, so much the better.
Your neighbour's toothbrush.

Points of note from my vast experience (doing it once):

Wiper arm very much seized: well worth making sure you have a suitable puller available. I used a small conventional / general purpose one, but you can get dedicated wiper ones. Regardless, a few days before pop of the plastic plugs, undo the nuts and dose up the area with penetrating fluid. Before using car, pop the nuts back on otherwise you'll get caught out!

Scuttle trim: remove bonnet seal. It's not obvious, but the back of the trim sits downwards in a channel that is pointing up to the sky, not forwards towards the front of the car. Start at one end and just work it out of the channel bit by bit.

Duct was a pain to get out: notes on my thread.

One of two torx hidden under scuttle trim was so rusted head was barely visible so had to Dremel it off. Was able to then Mole-Grip the remaining bit out later and put a self tapper with washer on at refit.

Once duct out of the way, you're really well on the way.

Only other thing of note was the flexi exhaust pipe that comes in from underneath (held by the 6mm's) gets in the way of the lower front 5mm. Rather than trying to pull it down I found it easier to slide it rearwards a little. Therefore undo the 6mm's first.

@depronman will confirm whether you need to block off the vacuum hose to stop the EGR from being activated again. Paul?

I blocked mine by means of the MIG welder, but it's being mapped out anyway.

Like all these things, as you're working outside, give the job a good dose of looking at over a couple of evenings or whatever so that you're 100% clear on where you're heading.

If it wasn't for the lock-down I'd say come over to mine and we could do it here. Two or three hours at a very leisurely pace would do it. I owe you a favour ?

This thread is excellent btw, and showed me everything:

 
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Anyhoo ... today, in readiness for a weekend of OSS one-man removal fun, stripped out lots of interior and got the headlining out. Eyed up next stages: I think we're good to go.

Also managed to unearth an ancient can of Wurth spray adhesive. Can't just nip out and buy anither of course, so needed to try and get this to work. Felt full but no signs of life. Soaked top of it in thinners whilst doing other things, drilled out the blocked nossle and success! It now sprays very well and the way my fingers ended up glued together very much suggests it'll reattach the flopped headlining just fine.

Shopping for seven people first thing but once that's all done I have as long as it takes to get the thing apart, out and tackling next steps. Actually looking forward to it, and this is where rescuing a scrapper really comes into its own: not much to lose!
 
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on thw AMF engine ONLY you can remove and plug the vacuum pipe to the EGR without any issue of fault codes and MIL lights, the reason for this is the AMF is a Euro3 engine.
You CANNOT do this on the BHC and ATL engines (they are both Euro4 engines), removing the vacuum pipe to the EGR on these engines will result in a fault code and associated MIL lights unless the EGR correctly mapped out

I also agree with Barry, the input of Exhaust gas into the bottom of the EGR valve is via a flexi pipe, which does hinder the removal of the lower corner retaining bolt (5mm hex), so if the 2off 6mm hex bolts that retain the exhaust flexi pipe to the EGR are removed first and the flexi pipe GENTLY moved backwards then access to the lower 5mm hex bolt is much improved. However be carefull not to bend the flexi too far else you will have a b****r of a job reattaching it to the EGR as access to it is very limited

Paul
 
As Paul says, you've got to take a look! It's really not that bad. As you know, I took my scuttle trim off as the wiper arm was off anyway, so did the 'air duct removed' method rather than the advanced 'grope around in the dark' method of the experts here.

Tools other than very standard stuff:

Pipe pliers to undo quick-clamps on various hoses.
Small torx (20/25?) for two screws for vent duct hidden under scuttle trim.
6mm allen with short side cut down to about 15mm overall.
5mm allen, longer the better but if standard size just refer to pic on my Break/Bale thread.
If you've got a T30 torx 'screwdriver' that works perfectly to quickly un-wind / loosely wind in the 5mm's.
Old container to wash the thing in. Use gloves!! The gunk basically turns to black ink.
Can carb / throttle body cleaner. Bit of old petrol from the mower.
Your neighbour's toothbrush.

Points of note from my vast experience (doing it once):

Wiper arm very much seized: well worth making sure you have a suitable puller available. I used a small conventional / general purpose one, but you can get dedicated wiper ones. Regardless, a few days before pop of the plastic plugs, undo the nuts and dose up the area with penetrating fluid. Before using car, pop the nuts back on otherwise you'll get caught out!

Scuttle trim: remove bonnet seal. It's not obvious, but the back of the trim sits downwards in a channel that is pointing up to the sky, not forwards towards the front of the car. Start at one end and just work it out of the channel bit by bit.

Duct was a pain to get out: notes on my thread.

One of two torx hidden under scuttle trim was so rusted head was barely visible so had to Dremel it off. Was able to then Mole-Grip the remaining bit out later and put a self tapper with washer on at refit.

Once duct out of the way, you're really well on the way.

Only other thing of note was the flexi exhaust pipe that comes in from underneath (held by the 6mm's) gets in the way of the lower front 5mm. Rather than trying to pull it down I found it easier to slide it rearwards a little. Therefore undo the 6mm's first.

@depronman will confirm whether you need to block off the vacuum hose to stop the EGR from being activated again. Paul?

I blocked mine by means of the MIG welder, but it's being mapped out anyway.

Like all these things, as you're working outside, give the job a good dose of looking at over a couple of evenings or whatever so that you're 100% clear on where you're heading.

If it wasn't for the lock-down I'd say come over to mine and we could do it here. Two or three hours at a very leisurely pace would do it. I owe you a favour ?

This thread is excellent btw, and showed me everything:

Excellent Barry (edit - and Paul!), thanks for that. I’ve done an EGR clean on a mk5 Golf and a Passat which were quite satisfying as they had a bit of room to work with, but the faff and misery of the thermostat, temperature sensor and flange fitting/refitting has left me scarred! I’ll give it a go when I can have 3 hours to myself, Sunday morning at 6am might be the ideal time to start!
 
I treated Spud to some similar pimping, with blue calipers and silver backplates front and rear. Jelly also got treated to new grooved discs and ceramic pads, had them for ages. Then painted calipers metallic red with silver backplates and similar on the rear drums. Well pleased.

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This post must be accompanied by a photo ?
 
Anyhoo ... today, in readiness for a weekend of OSS one-man removal fun, stripped out lots of interior and got the headlining out. Eyed up next stages: I think we're good to go.

Also managed to unearth an ancient can of Wurth spray adhesive. Can't just nip out and buy anither of course, so needed to try and get this to work. Felt full but no signs of life. Soaked top of it in thinners whilst doing other things, drilled out the blocked nossle and success! It now sprays very well and the way my fingers ended up glued together very much suggests it'll reattach the flopped headlining just fine.

Shopping for seven people first thing but once that's all done I have as long as it takes to get the thing apart, out and tackling next steps. Actually looking forward to it, and this is where rescuing a scrapper really comes into its own: not much to lose!

For removal, don’t forget the good old technique of lying on your back on the backs seats and pushing up with your legs to break the initial seal. It’s best the best technique I’ve used, you legs have the strength and control to do the job properly and about 20 OSS removals later I’ve only damaged 1 (with a stupid mistake)
 
For removal, don’t forget the good old technique of lying on your back on the backs seats and pushing up with your legs to break the initial seal. It’s best the best technique I’ve used, you legs have the strength and control to do the job properly and about 20 OSS removals later I’ve only damaged 1 (with a stupid mistake)

Don't worry: I've been well advised to 'use Steve's technique' so it's become quite famous I think :) I have read through your thread on removal several times and later on will give it a go. Keep an eye on the 'Wanted' section: if it's full of requests for OSS bits, you'll know it didn't go as well as I'd hoped :eek:
 
today I joined this site after now owning and a2 brought it a week before lockdown, tbh I didn't know much about them its a dark gray one fsh 72k miles on the clock brought it thinking id make a drink on it, but since its been sat on the drive as I cant mot it its growing on me, since sat on the drive iv done disc and pads all round, cambelt and water pump kit on (still had the one if left the factory with on it) d bushs and given it a good wash and hover out :)
 
.....discovered the hidden oil filler cap at the top of the engine whilst researching the securing bolts for the EGR valve that I’m planning to remove and clean. Logically I shouldn’t have been surprised to see it, but it did take my fuzzled brain a few moments to dawn on me what I was looking at.

So, I can see how to get to two of the hex head bolts securing it on, how do I get to the third bolt on the cabin side? Seems to be covered by a small metal plate secured by a couple of small Torx bolts, is that correct?
 

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.....discovered the hidden oil filler cap at the top of the engine whilst researching the securing bolts for the EGR valve that I’m planning to remove and clean. Logically I shouldn’t have been surprised to see it, but it did take my fuzzled brain a few moments to dawn on me what I was looking at.

So, I can see how to get to two of the hex head bolts securing it on, how do I get to the third bolt on the cabin side? Seems to be covered by a small metal plate secured by a couple of small Torx bolts, is that correct?
I think you're looking at the two vacuum chamber bracket screws: you can leave these on, the whole lot comes off together.

All you need to undo (assuming main inlet pipe is undone) is undo the three 5mm allens (two at the front, easily visible, and one around the back. If you check my thread, you can see the layout of these allens isn't equal, almost looks like one is missing.

Use my outback / redneck technique or similar if you don't have long enough allen key. Without getting personal, my one is quite short but still did the business quite easily.

To recap: two 6mms from underneath first which allows you to slide that pipe towards the bulkhead, freeing access to the lower front 5mm. Frankly, all of the allens are pretty easy: just don't drop them!

BTW, I can't be bothered to look this up as it's already been a long day, but suspect only a matter of time before my reference to 'allens' is going to get picked up :rolleyes:
 
So today

After 2 weeks of cleaning ,servicing and odd jobs , Basil is ready to return to the road ...
Very please with the results , and seriously considering buying a further TDI to refurbish once we allowed out again

Worst job was the EGR , followed by the CV boot replacement .. really need the right tool to “close “ the CV boot bands . also tracked down a rattle from the rear area , which turned out to be the battery ratting around under the mounting bracket, quickest job , replacing the bonnet plastic mounting things which the bonnet slides into at the rear
So next job is to re-paint the wing mirror covers in aluminium with a 2k clear top coat , and then starting to prep the rear spoiler which is coming early next week , via @Birchalls Son
Keep safe folks D4117E95-8510-4E1D-B940-8D60DFBE847A.jpeg1956B8B3-4C9E-4907-B633-FC56F04919B7.jpeg44CAB02B-C3B8-4741-B6F9-161C8E3B5DBA.png81547C82-7EFA-49BB-AFA7-E1E8DD434B44.jpegD4117E95-8510-4E1D-B940-8D60DFBE847A.jpeg
 
I think you're looking at the two vacuum chamber bracket screws: you can leave these on, the whole lot comes off together.

All you need to undo (assuming main inlet pipe is undone) is undo the three 5mm allens (two at the front, easily visible, and one around the back. If you check my thread, you can see the layout of these allens isn't equal, almost looks like one is missing.

Use my outback / redneck technique or similar if you don't have long enough allen key. Without getting personal, my one is quite short but still did the business quite easily.

To recap: two 6mms from underneath first which allows you to slide that pipe towards the bulkhead, freeing access to the lower front 5mm. Frankly, all of the allens are pretty easy: just don't drop them!

BTW, I can't be bothered to look this up as it's already been a long day, but suspect only a matter of time before my reference to 'allens' is going to get picked up :rolleyes:
Don’t worry worry, I’m sure most people on here are quite happy to call a spade a digging implement.....

I couldn’t see how to get to the third Allen/hex nut as it seems hidden, but I’ll have another look. Happily I have quite a long one which should make it give up without too much of a fight.
 
Today I serviced my OSS;

Cleaned out the old grease from the tracks.
Cleaned the seals with baby wipes.
Lubed the tracks with PTFE grease.
Lubed the seals with Silicone spray.
Lubed the pivot points with Silkopen.

Job done!

Simon.
 
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