I wonder how many of these TDIs you've saved by posting this trick online. Countless DIYers and garages have avoided heartache and expensive rebuilds with this one trick! You're doing us all a great service, Thomas!
Thanks for the fantastic advice. Jetta Mex TDI 2007 131k miles. EGR never cleaned. Same as yours with the dirt. Oil in the intercooler about 45 millimeters, however didn't make the whole for drain. Instead, removed the air hose and with a thick syringe and a plastic hose (the one I used to liquid moly purge diesel the injectors) suck out the oil. And at the end the remaining oil with a shop cloth removed it out from the intercooler. Just tested the car and running awesome. Thanks again for your videos, great help for the DYIers. Saludos amigo!
Just put a screw in the intercooler and got about 200ml of oil. Never had been done, I've had the car for 10 years, and it is a 2003 ALH. Did that first because next up is Intake clean and EGR Valve replacement (I understand it if it is weeping excessive oil then likely the diaphragm is torn). Valve on order. Thank you, as always, for this page!
Thanks Thomas, first thing i did when I cleaned the EGR Manifold and Turbo not much came out at 135k but i also drained it at 112 when i changed the timing belt PO said he changed Timing belt when I bought the car I pulled the cover and tensioner had a 02 date belt was worn all pulleys good I was lucky. Thanks for all you do for the tdi community.
I ran across a runaway diesel one time about 10 years ago on a 1984 Mercedes. Oh my god that was a sight to see. Got it to stop by stuffing every shop rag we had in the intake and it finally took the engine off.
I have a better one. Early 90's Audi turbodiesel, came to us ( when i was in Europe), had a complete engine rebuild, like everything pistons , bearings, head work, all. He didnt want to change the turbo as it was leaking oil. Car in our parking lot, he pays the bill, goes to start it, and gives it gas in neutral, like to test if it runs good after our work... IT RAN AWAY right there on the spot, ALMOST ruined all the work we did (and his bank account), luckily one of the mechanics jumped and blocked the intake, so no damage that we could find.... he came back in and ordered a new turbo.
That was really stopped up there. I'm not much of a fan on music, but must say that the music you picked while cleaning actually sounded pretty good. I found myself tapping my feet while it was playing :) A lot of new viewers will appreciate your advice about draining the oil from the intercooler. Keep up the good work Thomas!
I've never heard of a runaway because of this but then again, I've never owned a car with a turbo. Very interesting to know this. And wow, that was one plugged EGR.
It's a gradual power loss... they eventually notice it, like this guy did. Lower than normal MAF readings under boost points to a restriction of air flow. One of the first things I check is the intake.
Thx so much for this video Thomas, I am working on a Mercedes that the intake was full of carbon and now will be definitely cleaning that intercooler. I am glad that you post this. I will post a video on how much oil I get from this car. You just save me from a possible engine damage.
I got a video notice about your video... but I'm always late at getting to them. Thank you for dropping by again... I will do the same soon! Please record what you find / how much oil you drain... I would be interested in seeing this!
Well this E320 did not have much oil on the inter cooler just few drops. Didn't even worth to recorded. But either way thx for the advice. I will do that to every car that has one from now on.
I blanked off the EGR on the Focus when I got it and it has had a new Intercooler soon after doing that. That one should be nice and dry. The other car has more emissions stuff and could be an interesting one
Feeling so privileged just to hang out here and listen to you guys :-) It is a bit like talking to a deaf person. I listen and listen and watch... but not much stays in my head. But ... it is still quite sexy so I keep hanging out here XD (Until you throw me out :-)))
some great tips mate we don't seem to suffer that much blockage in are EGR valves over here don't get me wrong blocked but from what I can see on TH-cam over there you seem to get it worse than us what is the octane of your fuel
Thomas EXOVCDS I know my intercooler was never drained (alh as well) before I sold it at 375k a few weeks ago. I wonder how much oil it would have accumulated.
Low speed low boost city driving is what causes more to collect... the odd puff of blue out of the tailpipe under high rpm / boost, is the cooler oil being pushed through the system.
had a tubo go on me (cracked somewhere) they had power issues for about a month bit on it where power only felt like it was coming on at 3500rpm, i mostly worked out that it was likey turbo issue or air flow sensor faulty (as had air flow sensor go on me as the turbo would not open up it spool but would not activate) but that was not the end of it, when i was on the way back i put me foot on the clutch to change gear as you do take the foot of the accelerator little but it stayed at 2000 RPM , so pulled over turned engine off Still running at 2000RPM ish(on oil now) then it shot right up to i guess beyond max RPM for about 10 seconds then it sputtered off (guess i was lucky what ever oil had seeped out was not enough for it to keep on going for long) but sure made quite a slow moving smoke cloud , when we got it towed back the AA person just said start it to move it around i was like no, so he did it and it stared fine (after it puffed out the smoke in the exhaust system ) if i had known that i could of drove it back and kept it below 1500 RPM (turbo spools up above 1750RPM and opens up when power is needed after that) i really dont know how it did not run away on them when they was towing the caravan (maybe it was due to that i was attempting acceleration so all the way to 4000 RPM and was enough to get the turbo spinning or the oil in the intercooler into the engine lol) next time it happens i fully aware of it and that i should stop and drop the clutch before it gets above 3000-4000RPM as all i end up doing after that is burning the clutch out or blowing the gearbox this was a long time ago (at least i know what a EGR valve looks like now) the car i got has 250k miles on it not sure if it has ever been cleaned or drained on the intercooler (only paid £500 and done 10k miles on it, 1.9 PD engine UK) i have to ask if they have a look at it to make sure its all working fine (as i get what it sounds like a Air buzzing sound sometimes when i stop the engine gets slightly louder than blip at the end when it stops)
***** hmm - I'm not crazy with it so didn't get into smoke often. Had a DP box and 205 injectors (Jose and crew at JS performance in Abbotsford of you know them) so I might not have been too bad and owned since new. Having said that Jose might have done the intercooler on the egr replacement / intake manifold cleaning. They know tdis
well i did that oil drill but their is no oil coming out and i check the turbo he is on very good condition just little oil on turbo housing from pcv thank god
Great Video. Will this work on a 2006 VW 1.9 BEW Beetle? I have cleaned my EGR valve, shudder valve was just oily. Keeps throwing P2413 code. When I take it up a hill it throws a P0299 code and no power. Runs good with electrical plug to the EGR valve disconnected. Just put on a new turbo two months ago. What am I missing? Thanks
Make sure that vacuum supply to the actuator pod is ok and that the vacuum reservoir actually holds vacuum / does not bleed off. What about EGR cooler and cooler control flap (if there is one)?
Todor Radovanac Do it at ever oil change then... even better. Tell the customer that it was a free procedure and that it saves engines. They will appreciate it.... I know!
Wouldn't the (proper) way to drain it be to remove it and the charge pipes? I have 2 alh TDI cars. And a diesel truck. I've always pulled all charge pipes and intercoolers and given a thorough cleaning. It's definitely more work! But.....a better and result
Time is money... customers don't want to pay for that. Would you? Probably not, that why you do it yourself. It takes 5 min to drain & plug. Catch can or not, oil fumes will collect in the cooler / intake. Why fight it. 5min is all it takes / is all that is needed. I've been doing this for almost 10 years now. Haven't had any issues with any engines.
Hiya. Thanks for the video. Why is this operation done? I have a vw touran 1.9 tdi with BLS engine and automatic transmission and it has DPF. I cleaned the egr 2 years ago. It was dry but with soot around Egr. How do I clean that intercooler and how do I make a hole in my engine? thank you very much.
@@EXOVCDS Ok, but I also have to do it for the engine model BLS of my car? Now I don't know if I really have to do the same operation on my engine or not. thank you
@maryo2620 BLS is a PD engine. They don't have the same problem as the ALH engine. PD has electronic motor for EGR... ALH uses a vacuum operated valve to control EGR. Simply clean the carbon from around the electronic valve every year. Eventually, the EGR will fail (internal fault), then you can replace it. For now, as long as the engine doesn't have EGR faults, everything is ok.
@@EXOVCDS Thank you . I appreciate the prompt and professional response. Good health and keep up the great work you do with these videos. Many appreciations from me.
Want to do this to my AXR but I always think that is not good to drill the intercooler. Next time I do the timing belt I will ask the mechanic to unplug the intake as it was like that EGR and also to clean the intercooler .
I have drilled over 100 intercoolers by now, with no problems... I guess if my name isn't Eric The Car Guy, Scotty Kilmer or Humble Mechanic, I don't know what I'm doing.
@@nbgnc2111 Yeah, a lot of cruising (light throttle) below 2500 rpm. Low quantity air (low or no boost) & slow moving air (low rpm) does not carry oil out of the intercooler.
That...Was a lot of oil! :D I've seen so many of these engines carbon'd up like that, sometimes even worse than that one was! Makes me wonder if there's a design problem, or if it's just a "small diesel" issue.
Soot from the EGR plus oil vapor from the crankcase ventilation system equals black sludge in the intake. Plus the TDI engines use direct injection, so there's nothing washing the gunk out of the intake. Some of the gasoline direct injection engines have similar issues. Shortly after buying a Jetta TDI a little over a year ago, I stumbled across one of Thomas' videos where he shows how to clean the intake manifold. When I pulled the manifold off, it was so gunked-up I couldn't believe the engine ran! I also drilled and drained the intercooler. BIG THANK YOU to Thomas for making these videos.
Thank you for sharing this! Just got my first ALH TDI, also an '03. Question about drilling and draining the intercooler- are you drilling into plastic, metal, or both? I'm a paranoid sort and am thinking that if there's enough material to drill through that I'd drill and tap the intercooler with 1/8" npt and thread in a plug, as opposed to just a screw.
Do what makes sense to you... my drilling & draining videos couldn't be more simple to understand (I have several videos including pressure testing an intercooler with "just a screw".
This was 4 years ago but did you clean the whole intake outside the car? Or just the part you can see with the egr off? I did just the part you can see with the egr off and still have terrible fuel economy, so I'm wondering if its possibly restricted lower where I'd have to remove it to clean it
The intake was removed & cleaned. If you have good MAF & boost readings (actual is close to specified), then the intake is probably clean enough... but the only way to know is to remove it. Once the intake & ports (in the head) are clean, you can check if economy improves. If it did not make a difference, at least you know that the intake is clean / not the problem.
besides just knowing to look for that what would suggest that its getting clogged ? i got a 02 from a one owner that i have no clue if it ever been off and checked ? clock has 195k on it . im going to look soon just wondering
Lack of power... if you are used to the current power, then you might not know what it should be. Pulling the EGR / Intake flap is not too difficult. Watch one of my TDI Decarb videos... the first 5 minutes show intake flap removal. If you can't find the videos, let me know. I have an old one and a newer one... the newer one has better lighting.
Those eco boost engines have catch can kits you can put on. I watch the channel FordTechMaculuco and he went through and installed one. Any kits like that for VW's?
There are lots of different aftermarket catch can kits that can be spliced-in... I don't know of anything specific for specific VW / Audi engines. My customers don't like to spend money on extra stuff. Draining at every oil change is the simplest form of prevention.
Hi... no, your TDI uses a different design intercooler and has a better PCV system (does not have as bad of an oiling issues). Simply disconnect the in or out hose at the cooler to check for excessive oil.
At 7 years old... it's common that the sealing connections / o-rings will let some oil vapour past, causing stains. Any large leaks will / should set MAF or boost fault codes.
It’s abit worse then a stain I’d say, might try to pop it off and check it. It has high km at 256xxxkm but my buddies has 385xxxkm and all he has done was change the dsg fluid, oil changes, and timing belt.
If the intercooler was removed could it drain off?is this putting too much oil in?I recently seen oil seepage from my intercooler while doing a front wheel bearing...Audi a4 b5
Oil in the intercooler is normal (PCV fumes / oil particulates that collect over time). First generation TDI engines seem to collect the most (from what I have seen over the years). If your B5 cooler has never been checked, it probably has a bit of oil in it. It's a good idea to check it at every oil change... so you can catch PCV or Turbo issues at the early stage / before major damage occurs.
Watch this video... look how clean the screw is. If it were leaking, then the screw and the surrounding area would be oily. So no, not a boost leak. th-cam.com/video/f1EL5V1gAaw/w-d-xo.html Specifically at 1:15
laidaoui mohamed It's simple & cheap... once a screw is in place, it's even easier to check st every oil change. Let me know how much drained out after you drained it for the first time.
I drain all intercoolers (gas & diesel) of this style / shape... gasoline engines will also collect PCV fumes just like the diesel engines. Drain at every oil change so you can keep track of how quickly oil accumulates. Sudden rise in oil quantity will point towards a PCV or turbo issue.
If thats much oil in there, isnt there a lot of oil stuck to the "walls" in side the little passeges in the intercooler? Would it be wise ( i have a jetta mk5) to spray some Brake cleaner from the top and drain it through the hole? then blow air through to evaporate.. Would that be.,. overkill or.. advisable? Disolving it would actually clean it, since im sure some of it go all the way through the intake ..My thinking is that if a thin oil film is present in the fins of the intercooler, it would affect... the "cooling" part of the air passing by.. could be wrong. please advise. Thank you!
Over thinking it... I've said many times that "PCV fumes / oil" in the intake is normal. That's why the EGR gasses / soot sticks to the inside of the intake manifold and the intake gets carboned up over time. The only way to "stop" pcv oil from entering the intake system, is to vent the PCV fumes to atmosphere (illegal in some states / provinces). I ran my last turbo charged car "vented to atmosphere"... 7 years of driving and the inside of the intercooler was as clean (dirt / oil free) as the day that I installed it... I still have it and can post pictures of the inside. All you need to do is check the intercooler for excessive amounts of oil at every oil change... that way you can determine if there is a PCV or turbo issue (all of a sudden more oil than normal, points to a problem).
I see. I have EGR delete kit,with blockoff plates, and tuned it out, with a stage 2 tune from malone tuning. Isn't the PCV fumes... calculated? I was thinking of venting to atmosphere. Would i need any ecu adjustments?
i haven't checked my oil for a while in my alh and it was down just touching the dipstick just drained the intercooler yesterday about 7-10 tablespoons came out than i drained it today about 3-4 table spoons came out. im thinking its turbos bad but i checked it all is tight and spins good car smokes white for a bit till ever since ive had it its smoked a bit but i find it smokes a bit more now i guess ill just have to take it to my mechanic.
At minimum, just keep an eye on it (check it every week until you get a true baseline. If you got 7-10 the first time and 3-4 after 1 day, then you would have way more than 7 to 10 after a week, which you didn't have. 3-4 tablespoons is a bit much after 1 day... so yes, keep an eye on it. Replace the PCV puck on top of the valve cover... it's a check place to start with.
The diaphragm is supposed to flutter (allow & stop / restrict flow)... being oily and old, I wouldn't want to blow / suck on it to check it. I would just replace it... consider it a tune-up item. To isolate where the oil is coming from attach a hose to the valve and run it into a plastic coke bottle make a 1/2" hole (on the side of the bottle) to allow pressure to vent out (hose is attached into or around bottle opening). Block off the hose that goes to the turbo intake at the plastic intake tube. Now you can monitor how much oil is coming from the engine and how much from the turbo. Keep in mind that there will be less suction on the pcv now, since the air is not being pulled out like the turbo would be doing, but the engine will push blowby gasses out enough to get an idea if there is a pcv / blowby issue.
Thomas EXOVCDS so block off the little plastic hose that goes into the puck and put a hose from the puck to a bottle. do I drive it like that or just let it run ?
so to check the turbo side all the oil would be in my intercooler and to check the ccv it would be in the bottle. if it happens to be in the bottle of just need to replace the ccv puck ?
I'm not sure about fuel consumption... I guess it could, if the engine is not breathing right, but it will affect power / performance. A plugged intake can end up setting MAF or Boost fault codes. Removing the Intake Flap / EGR is easy (to check for carbon build up). If you have no excessive carbon issue, then look at actual boost values, cooling system / thermostat performance, dirty air filter, low tire pressure, dragging brakes etc (things that affect fuel economy).
@@EXOVCDS Thanks for your advice. Just drilled and drained the intercooler. Only about 3 ounces drained out. It had never been done before in 16 years as there was no drain screw. I put in a nice screw there. I also checked the EGR by removing the tube It was a bit black but not excessively carbed up There was a small amount of crust in the pipe further back. I don't think I will clean the manifold until there is a good 1/4" of solid carbon. The EGR did have a trickle of black oil dripping out the large hole dripping on to the cable. I did replace a caliper at the back as a hand break was not moving much. That might have been the issue. It is still a bit heavy on consumption. I may give the EGR valve a full remove and cleaning later this month.
Hey there. I have a golf 4 with an engine from a new beetle 1.8t ... and have a turbo that is leaking oil. I'm going to build everything apart. Could there be oil in my Intercooler to? The engine was swaped at 110k km now it has 240k
Any car, turbo or no turbo, diesel or gasoline... they will all have some oil in the intake system. Oil from PCV fumes. Too much oil can be a sign of an engine mechanical issue (too much piston ring blowby, bad PCV, bad turbo) that will need to be investigated.
Thank you for your quick response. Ok I had at least 200 to 250 ml in the Intercooler ... the turbo is about to be repaired at a repair service and I'm waiting for what the say.
Don’t know if you’re still active on this channel but I have some questions & you seem well versed in TDIs. Deleting the EGR wouldn’t solve the oil in your intercooler problem right? It’s from your turbo? So it’s completely normal to have some oil in your intercooler? Is there any way to prevent this besides a catch can?
I’ve read online that drilling a hole in your intercooler isn’t a good idea because even though it’s a screw with a washer it doesn’t seal it like it’s supposed to. If you have a lot of oil in your intercooler it’s probably your turbo that’s either bad or the “veins” are bad. So with a new turbo your oil in the intercooler should be non existent? What exactly is the point of an EGR delete if you still get oil in your intercooler? It’s to stop carbon build up I get that but it won’t help the oil situation in your intercooler at all correct? Thanks
Some oil is normal, yes... PCV oil. EGR delete is for people who are looking for more power & less carbon in the intake. Removing the EGR reduces fuel economy. Drill or not to drill.... do what makes you happy / feel better or go with the majority. I only state what works for me (I have proven results).
I highway drive my car 90 miles a day. 2800rpm 200,000 miles I check my anti shudder valve and it has never looked more then just lightly oiled. How does it get that bad?
@@EXOVCDS I commented on another video of yours a moment ago also. I have 04 bew and my lower intercooler pipe is starting to pop off. Anyone make a kit to convert it from c clip to spring clamp? I bought a new male/male flange aftermarket but I just don't like those c clip couplings in general. I don't like that it's clocked. Cause it seams to have torsion on it once I tighten down the thin plastic pipe going to the turbo.
What about the MK5 Jetta's with BRm engine, they have a front mounted intercooler, i took the lower hose off, no oil came out, it seems the low hose connection is very low so.. theoretically it shouldnt have oil rihgt?
Sadly oil from PCV that goes into intke right before the turbine baldes is seeping out at the o-ring that holds the intake to the turbo, i need to replace that. Oil is seeping out of it, and onto the metal hose that is hot of egr gases , not fun.
Hi Thomas I have a Awx 1.9tdi 130 Hp Audi Avant.(333,000 Kilometres) I have never cleaned out the intercooler,I have blocked my egr of but there is alot of oil around the weep holes of either side of the valve.Do you reckon my car would benefit from doing this? I would hazard a guess there is a small pool of oil in mine,Although i do regularly drive the car hard to just before the redlines and hold for up to a minute Thanks
Screwed a small hole into lowest point of intercooler,Around 10/20 Mls of clean oil came out,not bad for a 15 year old car,going to leave screw out tnyt and give car a good drive to clean out whats left and then put screw and rubber washer in.Will let you know if any issues.Cheers
Well drove the car for over 200 kilometres with the hole present and no loss of performance or boost,no issues of any kind,small few dribbles of oil next morning.Sealed the hole with rubber washer and screw.Worked a treat,will check regularly at service intervals.Works a treat and really easy now to monitor turbo seals and any blowpast.Cheers thomas
Hi Thomas, I recently had this done in a shop on my 2003 ALH with 320K kms. I had a clean intake manifold and an almost new EGR that were swapped in, to keep the downtime to a minimum. The shop also sucked out the oil from the intercooler bottom is what they told me. After that the power has been restored and the fuel economy numbers are good (around 5.3L/100kms). It's been about one month now. I'm noticing that on the EGR body, there's some black oil vapor seeping out of the small vent hole in the front, right under the shiny diaphragm. It's not a lot, but it's there. I've read online threads about this happening right after cleaning/re-installing the EGR. But in my case I installed a "new"ish EGR, and the intercooler oil was also flushed out. Is it normal for it to seep for sometime? Can the vent hole have some debris stuck that can be cleaned out by spraying some brake cleaner in there? I've seen an online thread that doing the cleaning of the vent hole solved the issue for someone. The vent hole in the rear of the EGR body is clean, no seepage there. Please let me know. Thanks.
There will always be oil "vapor" in the intake system... as long as the PCV is venting into the turbo inlet. Under boost, oil is forced against the intake tubing & manifold walls... looking for a way out. My guess is that the oil is traveling up the EGR valve stem (boost is pushing it up) where it ends up exiting at the vent hole. The vent hole is there to allow the diaphragm to function / move correctly. The guide for the valve is probably slightly worn... not much that can be done about it, as it is a sealed unit. Either wipe off the oil now & then or install a new unit.
@@EXOVCDS What's concerning is that it's a "new"ish unit and it's happening with that. I've cleaned it from the outside with brake cleaner. I also took a q-tip, sprayed some brake cleaner on it, and inserted that into the front vent where it was weeping. I gave a it a thorough scrubbing and it came out black as expected. I repeated with the other end of the q-tip. I've driven a few times after this and the weeping has not happened (knock on wood). I've also done the EGR adaptation as you've suggested in your other video. Thanks again.
@@CANADIANINDO New-ish is not new. It's a used unit that has had oil in it for some time. Every time the engine is producing boost, air pressure is forcing air / boost up the valve stem into the diaphragm chamber... where it then exits the vent hole with whatever oil had collected in there over time. The boost air in your engine also contains oil (PCV fumes)... that also get forced into the diaphragm chamber and out the vent. A new-new valve will have tighter EGR valve guide clearance and will probably less likely let oil pass by. Disconnect the PVC from the turbo inlet, to stop pcv oil / fumes from entering the engine. It will take some time (of driving) for the remaining oil in the system to disappear. Check your intercooler for excessive oil: th-cam.com/video/f1EL5V1gAaw/w-d-xo.html
@@EXOVCDS OK I understand that it's a used unit. Thanks for the detailed explanation on the inner workings of the EGR, it gives me a much better understanding now. The shop where I had the Intake and EGR replaced also sucked out the oil from the intercooler bottom is what they told me, so that's already taken care of. I'll keep an eye out for any more seepage out of the vent holes. Thanks again for all your help and guidance in your videos and replies, much appreciated.
I have many goals in life; getting married, being successful at work, etc. My biggest goal though? Getting Thomas to use a decent headlamp. Will you help me achieve this goal?
Jordan Ledbetter The problem is not with the headlamp... the problem is with the glasses. As soon as a spotlight from a headlamp is present, the camera darkens the surrounding area.
Hi , probably you don.t answer me but i.m gonna try anyway :)) , i have a mk4 tdi ajm is the motor code, i,ve buy it about 5-6 months ago , the vnt was stucked, i had it "cleaned" with some wd -40 trough the hot side of turbo and also i did the mr muscle thing and it moves nice and freely, but the problem is that when i start the car it comes a blue smoke and also when i rev the car at 2000+ rpm on stationary i had a blue smoke, when i drive it i never had a blue smoke only on stationary , what will it cause that ? injection ? or my turbo is going to let me..and also it's losing oil.. probably 1l at 3000 km or more ... if i drain the intercooler it will solve the problem..?
Draining the intercooler will not solve the problem, but it can tell you if there is a Turbo or PCV problem. Could be Turbo or Injector. Remove the glow plugs and check if one is dirtier or cleaner than the others. Remove the exhaust pipe from the turbo and check if the turbine wheel is oily. Remove the air hose from the turbo (air outlet) and check for excessive oil.
@@EXOVCDS Hi, i remove the exausht pipe from turbo and is not oily , and at the air hose from the turbo is like a 2 drop of oil there i don,t know if that is ok, i removed the turbo completely and the bearings i think its called it has a little bit of move like left and right, but in and out it doesn.t have any move at all , at glow plugs i have to go to a service because i don,t want to break those
@@EXOVCDShonestly i think it's smell like burn or something like that but doesn,t smell of fuel ... when this coronavirus is over i.m gonna drain the intercooler because i don t think the previous owner did that at all but what do i do with the oile from the intercooler do i get rid of it ?
@@eduardcatalin1993 It probably won't be much oil, so you can soak it up with a rag and then toss the rag in a fire pit. If it's more than 250ml, you can remove the oil filler cap and pour it in there. I asked about fuel smell because a leaky injector or injector o-ring can cause diesel to leak into the oil. The reason it does not smoke when you are driving, is because the engine has boost when "driving". Boost = more air... more air helps stuff burn better. At least that's my guess as to why you don't see the smoke when driving. Also, the smoke disappears quicker when you are driving (mixes with rushing air from around the car). The engine would have to smoke very much, for you to see it while driving.
@@EXOVCDS hi sir, Thanks for helping on my immobilizer issue. Worked just how you said it would. Another issue is exactly what you speak of in this video. What I wanted to know was if you replace the turbo or PCV, whichever is giving the issue. Would it stop collecting oil in the intercooler or would it just be less?
I wonder how many of these TDIs you've saved by posting this trick online. Countless DIYers and garages have avoided heartache and expensive rebuilds with this one trick! You're doing us all a great service, Thomas!
Thank you for the kind words... the majority of people / owners / garages still don't do this / find it not acceptable. =(
Thanks for the fantastic advice. Jetta Mex TDI 2007 131k miles. EGR never cleaned. Same as yours with the dirt. Oil in the intercooler about 45 millimeters, however didn't make the whole for drain. Instead, removed the air hose and with a thick syringe and a plastic hose (the one I used to liquid moly purge diesel the injectors) suck out the oil. And at the end the remaining oil with a shop cloth removed it out from the intercooler. Just tested the car and running awesome. Thanks again for your videos, great help for the DYIers. Saludos amigo!
There are many ways to remove the oil... some ways are quicker than others. =)
Thank you for watching!
Just put a screw in the intercooler and got about 200ml of oil. Never had been done, I've had the car for 10 years, and it is a 2003 ALH.
Did that first because next up is Intake clean and EGR Valve replacement (I understand it if it is weeping excessive oil then likely the diaphragm is torn). Valve on order.
Thank you, as always, for this page!
Thank you for sharing and thank you for watching!
I'm glad you caught it cause if it had runaway and being 14yrs old the Amber Alert would have interrupted my television show.
LOL!
Thanks Thomas, first thing i did when I cleaned the EGR Manifold and Turbo not much came out at 135k but i also drained it at 112 when i changed the timing belt PO said he changed Timing belt when I bought the car I pulled the cover and tensioner had a 02 date belt was worn all pulleys good I was lucky. Thanks for all you do for the tdi community.
Thank you for watching!
I ran across a runaway diesel one time about 10 years ago on a 1984 Mercedes. Oh my god that was a sight to see. Got it to stop by stuffing every shop rag we had in the intake and it finally took the engine off.
I had one blow up on me on a test drive... after I cleaned the carbon out of the intake. Since then, I check / drain all intercoolers, diesel & gas.
Thomas EXOVCDS The guy next to me was working on it and put the linkage on wrong and when you hit the gas he held it wide open.
Ouch!
I have a better one. Early 90's Audi turbodiesel, came to us ( when i was in Europe), had a complete engine rebuild, like everything pistons , bearings, head work, all. He didnt want to change the turbo as it was leaking oil. Car in our parking lot, he pays the bill, goes to start it, and gives it gas in neutral, like to test if it runs good after our work... IT RAN AWAY right there on the spot, ALMOST ruined all the work we did (and his bank account), luckily one of the mechanics jumped and blocked the intake, so no damage that we could find.... he came back in and ordered a new turbo.
semecristian Lucky customer!
That was really stopped up there. I'm not much of a fan on music, but must say that the music you picked while cleaning actually sounded pretty good. I found myself tapping my feet while it was playing :) A lot of new viewers will appreciate your advice about draining the oil from the intercooler. Keep up the good work Thomas!
Thanks for reminding me!!! I forgot to add a music credit to the description! =)
Thanks for the link Thomas and I just bookmarked it. Oh, I found the song on the site :)
I've never heard of a runaway because of this but then again, I've never owned a car with a turbo. Very interesting to know this. And wow, that was one plugged EGR.
Only diesels run away. Even naturally aspirated diesels can run away if they somehow get oil leaking into the intake
Shocking that vehicle owners can't feel the performance degradation long before it comes to this! Nice work and great tips!
It's a gradual power loss... they eventually notice it, like this guy did. Lower than normal MAF readings under boost points to a restriction of air flow. One of the first things I check is the intake.
Oh we feel it more in the pocket so we just live with it.
Thx so much for this video Thomas, I am working on a Mercedes that the intake was full of carbon and now will be definitely cleaning that intercooler. I am glad that you post this. I will post a video on how much oil I get from this car. You just save me from a possible engine damage.
I got a video notice about your video... but I'm always late at getting to them. Thank you for dropping by again... I will do the same soon! Please record what you find / how much oil you drain... I would be interested in seeing this!
Well this E320 did not have much oil on the inter cooler just few drops. Didn't even worth to recorded. But either way thx for the advice. I will do that to every car that has one from now on.
Every time I see you do this I have to wonder how many other shops think of doing this. That's a lot of oil. 😂😂
I bet less than 5%!
I might have to try it on my diesel fleet
I'd be interested in what you find! Don't forget to record!
I blanked off the EGR on the Focus when I got it and it has had a new Intercooler soon after doing that. That one should be nice and dry. The other car has more emissions stuff and could be an interesting one
Feeling so privileged just to hang out here and listen to you guys :-) It is a bit like talking to a deaf person. I listen and listen and watch... but not much stays in my head. But ... it is still quite sexy so I keep hanging out here XD (Until you throw me out :-)))
some great tips mate we don't seem to suffer that much blockage in are EGR valves over here don't get me wrong blocked but from what I can see on TH-cam over there you seem to get it worse than us what is the octane of your fuel
Sorry, don't know the specs of the diesel that is sold here... I just know that there is a cheap version and a premium version.
A thousand thank yous , question would you ever block off the vacuum to the egr on a 2000 1.9 alh motor ,
No... it will set a fault code / turn the check engine light on. You get better fuel economy with a functional EGR.
so cool! I had no idea that's why a diesel engine would run away but it totally makes sense.
It's a scary & expensive occurrence!
Thomas EXOVCDS I know my intercooler was never drained (alh as well) before I sold it at 375k a few weeks ago. I wonder how much oil it would have accumulated.
Low speed low boost city driving is what causes more to collect... the odd puff of blue out of the tailpipe under high rpm / boost, is the cooler oil being pushed through the system.
had a tubo go on me (cracked somewhere) they had power issues for about a month bit on it where power only felt like it was coming on at 3500rpm, i mostly worked out that it was likey turbo issue or air flow sensor faulty (as had air flow sensor go on me as the turbo would not open up it spool but would not activate)
but that was not the end of it, when i was on the way back i put me foot on the clutch to change gear as you do take the foot of the accelerator little but it stayed at 2000 RPM , so pulled over turned engine off Still running at 2000RPM ish(on oil now) then it shot right up to i guess beyond max RPM for about 10 seconds then it sputtered off (guess i was lucky what ever oil had seeped out was not enough for it to keep on going for long) but sure made quite a slow moving smoke cloud ,
when we got it towed back the AA person just said start it to move it around i was like no, so he did it and it stared fine (after it puffed out the smoke in the exhaust system ) if i had known that i could of drove it back and kept it below 1500 RPM (turbo spools up above 1750RPM and opens up when power is needed after that)
i really dont know how it did not run away on them when they was towing the caravan (maybe it was due to that i was attempting acceleration so all the way to 4000 RPM and was enough to get the turbo spinning or the oil in the intercooler into the engine lol) next time it happens i fully aware of it and that i should stop and drop the clutch before it gets above 3000-4000RPM as all i end up doing after that is burning the clutch out or blowing the gearbox
this was a long time ago (at least i know what a EGR valve looks like now) the car i got has 250k miles on it not sure if it has ever been cleaned or drained on the intercooler (only paid £500 and done 10k miles on it, 1.9 PD engine UK) i have to ask if they have a look at it to make sure its all working fine (as i get what it sounds like a Air buzzing sound sometimes when i stop the engine gets slightly louder than blip at the end when it stops)
***** hmm - I'm not crazy with it so didn't get into smoke often. Had a DP box and 205 injectors (Jose and crew at JS performance in Abbotsford of you know them) so I might not have been too bad and owned since new. Having said that Jose might have done the intercooler on the egr replacement / intake manifold cleaning. They know tdis
That was at least a 2 beer wait for the oil to drain 🍻
Are you confirming or suggesting for next time! LOL
well i did that oil drill but their is no oil coming out and i check the turbo he is on very good condition just little oil on turbo housing from pcv thank god
That's very good! Easy to check this way... yes? =)
ofc thank you for this great idea
Great Video. Will this work on a 2006 VW 1.9 BEW Beetle? I have cleaned my EGR valve, shudder valve was just oily. Keeps throwing P2413 code. When I take it up a hill it throws a P0299 code and no power. Runs good with electrical plug to the EGR valve disconnected. Just put on a new turbo two months ago. What am I missing? Thanks
Make sure that vacuum supply to the actuator pod is ok and that the vacuum reservoir actually holds vacuum / does not bleed off. What about EGR cooler and cooler control flap (if there is one)?
WOW!! Thanks for this video, didn't even know you could drain intercooler like that!!!
Lots of people seem to be against it... hmmmm.
I thinks if I suggested this to my boss after every EGR change he would go crazy. Yeah you are right, a lot of people are against it!
Todor Radovanac Do it at ever oil change then... even better. Tell the customer that it was a free procedure and that it saves engines. They will appreciate it.... I know!
Wouldn't the (proper) way to drain it be to remove it and the charge pipes? I have 2 alh TDI cars. And a diesel truck. I've always pulled all charge pipes and intercoolers and given a thorough cleaning. It's definitely more work! But.....a better and result
Time is money... customers don't want to pay for that. Would you? Probably not, that why you do it yourself. It takes 5 min to drain & plug. Catch can or not, oil fumes will collect in the cooler / intake. Why fight it. 5min is all it takes / is all that is needed. I've been doing this for almost 10 years now. Haven't had any issues with any engines.
Hiya. Thanks for the video. Why is this operation done? I have a vw touran 1.9 tdi with BLS engine and automatic transmission and it has DPF. I cleaned the egr 2 years ago. It was dry but with soot around Egr. How do I clean that intercooler and how do I make a hole in my engine? thank you very much.
This does not apply to your engine. ALH not BLS.
@@EXOVCDS Ok, but I also have to do it for the engine model BLS of my car? Now I don't know if I really have to do the same operation on my engine or not. thank you
@maryo2620
BLS is a PD engine. They don't have the same problem as the ALH engine. PD has electronic motor for EGR... ALH uses a vacuum operated valve to control EGR.
Simply clean the carbon from around the electronic valve every year. Eventually, the EGR will fail (internal fault), then you can replace it. For now, as long as the engine doesn't have EGR faults, everything is ok.
@@EXOVCDS Thank you . I appreciate the prompt and professional response. Good health and keep up the great work you do with these videos. Many appreciations from me.
Want to do this to my AXR but I always think that is not good to drill the intercooler. Next time I do the timing belt I will ask the mechanic to unplug the intake as it was like that EGR and also to clean the intercooler .
I have drilled over 100 intercoolers by now, with no problems... I guess if my name isn't Eric The Car Guy, Scotty Kilmer or Humble Mechanic, I don't know what I'm doing.
bbogdanmircea i do it too, s4 2.7tt, 1.8t, 1.9 and 2 liter turbo never had any problem on more than 30psi
When it comes to VW/Audi i trust your knowledge 100%. If you told me to drill a hole in the air bag i probably would. {:>)
LOL, thanks Bill!
why does oil build up there? what causes it?
Low point of the air intake system... stop & go, low rpm city driving.
@@nbgnc2111 Yeah, a lot of cruising (light throttle) below 2500 rpm. Low quantity air (low or no boost) & slow moving air (low rpm) does not carry oil out of the intercooler.
@@nbgnc2111 Click on fkh161 in the description and then click "tool request" to send me the picture.
@@nbgnc2111 I haven't received anything yet.
That...Was a lot of oil! :D
I've seen so many of these engines carbon'd up like that, sometimes even worse than that one was! Makes me wonder if there's a design problem, or if it's just a "small diesel" issue.
I think it's driving habits... stop & go, low rpm trips. If the oil wasn't there, there'd be less buildup also.
Soot from the EGR plus oil vapor from the crankcase ventilation system equals black sludge in the intake. Plus the TDI engines use direct injection, so there's nothing washing the gunk out of the intake. Some of the gasoline direct injection engines have similar issues.
Shortly after buying a Jetta TDI a little over a year ago, I stumbled across one of Thomas' videos where he shows how to clean the intake manifold. When I pulled the manifold off, it was so gunked-up I couldn't believe the engine ran! I also drilled and drained the intercooler. BIG THANK YOU to Thomas for making these videos.
Thanks for the advice. Appreciate it
Thank you for sharing this! Just got my first ALH TDI, also an '03. Question about drilling and draining the intercooler- are you drilling into plastic, metal, or both? I'm a paranoid sort and am thinking that if there's enough material to drill through that I'd drill and tap the intercooler with 1/8" npt and thread in a plug, as opposed to just a screw.
Do what makes sense to you... my drilling & draining videos couldn't be more simple to understand (I have several videos including pressure testing an intercooler with "just a screw".
This was 4 years ago but did you clean the whole intake outside the car? Or just the part you can see with the egr off? I did just the part you can see with the egr off and still have terrible fuel economy, so I'm wondering if its possibly restricted lower where I'd have to remove it to clean it
The intake was removed & cleaned.
If you have good MAF & boost readings (actual is close to specified), then the intake is probably clean enough... but the only way to know is to remove it. Once the intake & ports (in the head) are clean, you can check if economy improves. If it did not make a difference, at least you know that the intake is clean / not the problem.
This system with screw are secure for Air leaks at high power demand?
No air leaks.
besides just knowing to look for that what would suggest that its getting clogged ? i got a 02 from a one owner that i have no clue if it ever been off and checked ?
clock has 195k on it . im going to look soon just wondering
Lack of power... if you are used to the current power, then you might not know what it should be. Pulling the EGR / Intake flap is not too difficult. Watch one of my TDI Decarb videos... the first 5 minutes show intake flap removal. If you can't find the videos, let me know. I have an old one and a newer one... the newer one has better lighting.
Those eco boost engines have catch can kits you can put on. I watch the channel FordTechMaculuco and he went through and installed one. Any kits like that for VW's?
There are lots of different aftermarket catch can kits that can be spliced-in... I don't know of anything specific for specific VW / Audi engines. My customers don't like to spend money on extra stuff. Draining at every oil change is the simplest form of prevention.
The intake shut-off flap would have stopped any potential runaway, wouldn't it?
One would hope / think so... but it doesn't always.
Hey man good to see your so close in B.C. to me, I have a 2012 tdi Jetta. Will I need to drain in the same spot?
Hi... no, your TDI uses a different design intercooler and has a better PCV system (does not have as bad of an oiling issues). Simply disconnect the in or out hose at the cooler to check for excessive oil.
Okay thanks, it just has oil sweating from the bottom intercooler hose and I think it has quite the oil caked up or something...
At 7 years old... it's common that the sealing connections / o-rings will let some oil vapour past, causing stains. Any large leaks will / should set MAF or boost fault codes.
It’s abit worse then a stain I’d say, might try to pop it off and check it. It has high km at 256xxxkm but my buddies has 385xxxkm and all he has done was change the dsg fluid, oil changes, and timing belt.
If the intercooler was removed could it drain off?is this putting too much oil in?I recently seen oil seepage from my intercooler while doing a front wheel bearing...Audi a4 b5
Oil in the intercooler is normal (PCV fumes / oil particulates that collect over time). First generation TDI engines seem to collect the most (from what I have seen over the years). If your B5 cooler has never been checked, it probably has a bit of oil in it. It's a good idea to check it at every oil change... so you can catch PCV or Turbo issues at the early stage / before major damage occurs.
@@EXOVCDS thank you👍subscribed also...great content in your videos👌
@@whatsup8464 Thank you and thank you for watching!
Thank You very much for great information and help sir.
Thank you for watching!
how many km was on this? That engine looked clean!
140k km.
Wouldnt you lose some pressure under boost with that hole there? I feel like a screw isnt going to seal it completely
Watch this video... look how clean the screw is. If it were leaking, then the screw and the surrounding area would be oily. So no, not a boost leak.
th-cam.com/video/f1EL5V1gAaw/w-d-xo.html
Specifically at 1:15
Did you watch the video.. did it make sense?
very good idea i will do it on my engine because i have that oil drill too thank you
laidaoui mohamed It's simple & cheap... once a screw is in place, it's even easier to check st every oil change. Let me know how much drained out after you drained it for the first time.
ok i will next oil change in 2000km
@@elhachemiable- so how much came out? you must have changed the oil by now.
would this also help with the AWP 1.8t (drain the intercooler)or only the ALH
I drain all intercoolers (gas & diesel) of this style / shape... gasoline engines will also collect PCV fumes just like the diesel engines. Drain at every oil change so you can keep track of how quickly oil accumulates. Sudden rise in oil quantity will point towards a PCV or turbo issue.
If thats much oil in there, isnt there a lot of oil stuck to the "walls" in side the little passeges in the intercooler? Would it be wise ( i have a jetta mk5) to spray some Brake cleaner from the top and drain it through the hole? then blow air through to evaporate.. Would that be.,. overkill or.. advisable? Disolving it would actually clean it, since im sure some of it go all the way through the intake ..My thinking is that if a thin oil film is present in the fins of the intercooler, it would affect... the "cooling" part of the air passing by.. could be wrong. please advise. Thank you!
Over thinking it... I've said many times that "PCV fumes / oil" in the intake is normal. That's why the EGR gasses / soot sticks to the inside of the intake manifold and the intake gets carboned up over time. The only way to "stop" pcv oil from entering the intake system, is to vent the PCV fumes to atmosphere (illegal in some states / provinces). I ran my last turbo charged car "vented to atmosphere"... 7 years of driving and the inside of the intercooler was as clean (dirt / oil free) as the day that I installed it... I still have it and can post pictures of the inside. All you need to do is check the intercooler for excessive amounts of oil at every oil change... that way you can determine if there is a PCV or turbo issue (all of a sudden more oil than normal, points to a problem).
I see. I have EGR delete kit,with blockoff plates, and tuned it out, with a stage 2 tune from malone tuning. Isn't the PCV fumes... calculated? I was thinking of venting to atmosphere. Would i need any ecu adjustments?
No.
i haven't checked my oil for a while in my alh and it was down just touching the dipstick just drained the intercooler yesterday about 7-10 tablespoons came out than i drained it today about 3-4 table spoons came out. im thinking its turbos bad but i checked it all is tight and spins good car smokes white for a bit till ever since ive had it its smoked a bit but i find it smokes a bit more now i guess ill just have to take it to my mechanic.
At minimum, just keep an eye on it (check it every week until you get a true baseline. If you got 7-10 the first time and 3-4 after 1 day, then you would have way more than 7 to 10 after a week, which you didn't have. 3-4 tablespoons is a bit much after 1 day... so yes, keep an eye on it. Replace the PCV puck on top of the valve cover... it's a check place to start with.
Thomas EXOVCDS anyway to test the puck ? I blew in it air went out with no problem.
The diaphragm is supposed to flutter (allow & stop / restrict flow)... being oily and old, I wouldn't want to blow / suck on it to check it. I would just replace it... consider it a tune-up item. To isolate where the oil is coming from attach a hose to the valve and run it into a plastic coke bottle make a 1/2" hole (on the side of the bottle) to allow pressure to vent out (hose is attached into or around bottle opening). Block off the hose that goes to the turbo intake at the plastic intake tube. Now you can monitor how much oil is coming from the engine and how much from the turbo. Keep in mind that there will be less suction on the pcv now, since the air is not being pulled out like the turbo would be doing, but the engine will push blowby gasses out enough to get an idea if there is a pcv / blowby issue.
Thomas EXOVCDS so block off the little plastic hose that goes into the puck and put a hose from the puck to a bottle. do I drive it like that or just let it run ?
so to check the turbo side all the oil would be in my intercooler and to check the ccv it would be in the bottle. if it happens to be in the bottle of just need to replace the ccv puck ?
Thomas hi how is it going? Would this at some point pump an error code out? Also would a clogged egr valve cause high fuel usage?
I'm not sure about fuel consumption... I guess it could, if the engine is not breathing right, but it will affect power / performance. A plugged intake can end up setting MAF or Boost fault codes. Removing the Intake Flap / EGR is easy (to check for carbon build up). If you have no excessive carbon issue, then look at actual boost values, cooling system / thermostat performance, dirty air filter, low tire pressure, dragging brakes etc (things that affect fuel economy).
@@EXOVCDS Thanks for your advice. Just drilled and drained the intercooler. Only about 3 ounces drained out. It had never been done before in 16 years as there was no drain screw. I put in a nice screw there. I also checked the EGR by removing the tube It was a bit black but not excessively carbed up There was a small amount of crust in the pipe further back. I don't think I will clean the manifold until there is a good 1/4" of solid carbon. The EGR did have a trickle of black oil dripping out the large hole dripping on to the cable. I did replace a caliper at the back as a hand break was not moving much. That might have been the issue. It is still a bit heavy on consumption. I may give the EGR valve a full remove and cleaning later this month.
Thank you for the update!
Hey there.
I have a golf 4 with an engine from a new beetle 1.8t ... and have a turbo that is leaking oil. I'm going to build everything apart. Could there be oil in my Intercooler to? The engine was swaped at 110k km now it has 240k
Any car, turbo or no turbo, diesel or gasoline... they will all have some oil in the intake system. Oil from PCV fumes. Too much oil can be a sign of an engine mechanical issue (too much piston ring blowby, bad PCV, bad turbo) that will need to be investigated.
Thank you for your quick response.
Ok I had at least 200 to 250 ml in the Intercooler ... the turbo is about to be repaired at a repair service and I'm waiting for what the say.
Don’t know if you’re still active on this channel but I have some questions & you seem well versed in TDIs. Deleting the EGR wouldn’t solve the oil in your intercooler problem right? It’s from your turbo? So it’s completely normal to have some oil in your intercooler? Is there any way to prevent this besides a catch can?
I’ve read online that drilling a hole in your intercooler isn’t a good idea because even though it’s a screw with a washer it doesn’t seal it like it’s supposed to. If you have a lot of oil in your intercooler it’s probably your turbo that’s either bad or the “veins” are bad. So with a new turbo your oil in the intercooler should be non existent? What exactly is the point of an EGR delete if you still get oil in your intercooler? It’s to stop carbon build up I get that but it won’t help the oil situation in your intercooler at all correct? Thanks
Some oil is normal, yes... PCV oil.
EGR delete is for people who are looking for more power & less carbon in the intake.
Removing the EGR reduces fuel economy.
Drill or not to drill.... do what makes you happy / feel better or go with the majority.
I only state what works for me (I have proven results).
I highway drive my car 90 miles a day. 2800rpm 200,000 miles I check my anti shudder valve and it has never looked more then just lightly oiled. How does it get that bad?
Stop & go city driving, not getting up to temperature, low rpm.
@@EXOVCDS I commented on another video of yours a moment ago also. I have 04 bew and my lower intercooler pipe is starting to pop off. Anyone make a kit to convert it from c clip to spring clamp? I bought a new male/male flange aftermarket but I just don't like those c clip couplings in general. I don't like that it's clocked. Cause it seams to have torsion on it once I tighten down the thin plastic pipe going to the turbo.
@@electromechanicalstuff2602 you can convert to the earlier version setup (ALH engine).
amazing and clear video
Thank you and thank you for watching!
What about the MK5 Jetta's with BRm engine, they have a front mounted intercooler, i took the lower hose off, no oil came out, it seems the low hose connection is very low so.. theoretically it shouldnt have oil rihgt?
Yes... if you don't see any at the lower hose, things are good.
Some oil from PCV is normal.
Sadly oil from PCV that goes into intke right before the turbine baldes is seeping out at the o-ring that holds the intake to the turbo, i need to replace that. Oil is seeping out of it, and onto the metal hose that is hot of egr gases , not fun.
semecristian Stuff dripping on the exhaust is the worst... the smell gets into the car and is quite unpleasant (as well as not healthy).
Hi Thomas
I have a Awx 1.9tdi 130 Hp Audi Avant.(333,000 Kilometres)
I have never cleaned out the intercooler,I have blocked my egr of but there is alot of oil around the weep holes of either side of the valve.Do you reckon my car would benefit from doing this? I would hazard a guess there is a small pool of oil in mine,Although i do regularly drive the car hard to just before the redlines and hold for up to a minute
Thanks
Checking the cooler takes less time than what you just typed with a keyboard. =)
That was a yes... can't hurt to check / drain.
thanks thomas appriciated :)
Screwed a small hole into lowest point of intercooler,Around 10/20 Mls of clean oil came out,not bad for a 15 year old car,going to leave screw out tnyt and give car a good drive to clean out whats left and then put screw and rubber washer in.Will let you know if any issues.Cheers
Well drove the car for over 200 kilometres with the hole present and no loss of performance or boost,no issues of any kind,small few dribbles of oil next morning.Sealed the hole with rubber washer and screw.Worked a treat,will check regularly at service intervals.Works a treat and really easy now to monitor turbo seals and any blowpast.Cheers thomas
Hi Thomas, I recently had this done in a shop on my 2003 ALH with 320K kms. I had a clean intake manifold and an almost new EGR that were swapped in, to keep the downtime to a minimum. The shop also sucked out the oil from the intercooler bottom is what they told me. After that the power has been restored and the fuel economy numbers are good (around 5.3L/100kms). It's been about one month now. I'm noticing that on the EGR body, there's some black oil vapor seeping out of the small vent hole in the front, right under the shiny diaphragm. It's not a lot, but it's there. I've read online threads about this happening right after cleaning/re-installing the EGR. But in my case I installed a "new"ish EGR, and the intercooler oil was also flushed out. Is it normal for it to seep for sometime? Can the vent hole have some debris stuck that can be cleaned out by spraying some brake cleaner in there? I've seen an online thread that doing the cleaning of the vent hole solved the issue for someone. The vent hole in the rear of the EGR body is clean, no seepage there. Please let me know. Thanks.
There will always be oil "vapor" in the intake system... as long as the PCV is venting into the turbo inlet. Under boost, oil is forced against the intake tubing & manifold walls... looking for a way out. My guess is that the oil is traveling up the EGR valve stem (boost is pushing it up) where it ends up exiting at the vent hole. The vent hole is there to allow the diaphragm to function / move correctly. The guide for the valve is probably slightly worn... not much that can be done about it, as it is a sealed unit. Either wipe off the oil now & then or install a new unit.
@@EXOVCDS What's concerning is that it's a "new"ish unit and it's happening with that. I've cleaned it from the outside with brake cleaner. I also took a q-tip, sprayed some brake cleaner on it, and inserted that into the front vent where it was weeping. I gave a it a thorough scrubbing and it came out black as expected. I repeated with the other end of the q-tip. I've driven a few times after this and the weeping has not happened (knock on wood). I've also done the EGR adaptation as you've suggested in your other video. Thanks again.
@@CANADIANINDO New-ish is not new. It's a used unit that has had oil in it for some time. Every time the engine is producing boost, air pressure is forcing air / boost up the valve stem into the diaphragm chamber... where it then exits the vent hole with whatever oil had collected in there over time. The boost air in your engine also contains oil (PCV fumes)... that also get forced into the diaphragm chamber and out the vent. A new-new valve will have tighter EGR valve guide clearance and will probably less likely let oil pass by. Disconnect the PVC from the turbo inlet, to stop pcv oil / fumes from entering the engine. It will take some time (of driving) for the remaining oil in the system to disappear. Check your intercooler for excessive oil:
th-cam.com/video/f1EL5V1gAaw/w-d-xo.html
@@EXOVCDS OK I understand that it's a used unit. Thanks for the detailed explanation on the inner workings of the EGR, it gives me a much better understanding now. The shop where I had the Intake and EGR replaced also sucked out the oil from the intercooler bottom is what they told me, so that's already taken care of. I'll keep an eye out for any more seepage out of the vent holes. Thanks again for all your help and guidance in your videos and replies, much appreciated.
This trick can be applied on 1.8T VW Audi?
Yes.
th-cam.com/video/vdM2WTNZHcs/w-d-xo.html
I assumed you are talking about draining the intercooler?
I have many goals in life; getting married, being successful at work, etc. My biggest goal though? Getting Thomas to use a decent headlamp.
Will you help me achieve this goal?
Jordan Ledbetter The problem is not with the headlamp... the problem is with the glasses. As soon as a spotlight from a headlamp is present, the camera darkens the surrounding area.
Very helpful tip!
Thank you for watching!
Finish job to the end. There is a lot of oil left inside....
No there isn't.
Hi , probably you don.t answer me but i.m gonna try anyway :)) , i have a mk4 tdi ajm is the motor code, i,ve buy it about 5-6 months ago , the vnt was stucked, i had it "cleaned" with some wd -40 trough the hot side of turbo and also i did the mr muscle thing and it moves nice and freely, but the problem is that when i start the car it comes a blue smoke and also when i rev the car at 2000+ rpm on stationary i had a blue smoke, when i drive it i never had a blue smoke only on stationary , what will it cause that ? injection ? or my turbo is going to let me..and also it's losing oil.. probably 1l at 3000 km or more ... if i drain the intercooler it will solve the problem..?
Draining the intercooler will not solve the problem, but it can tell you if there is a Turbo or PCV problem. Could be Turbo or Injector. Remove the glow plugs and check if one is dirtier or cleaner than the others. Remove the exhaust pipe from the turbo and check if the turbine wheel is oily. Remove the air hose from the turbo (air outlet) and check for excessive oil.
@@EXOVCDS Hi, i remove the exausht pipe from turbo and is not oily , and at the air hose from the turbo is like a 2 drop of oil there i don,t know if that is ok, i removed the turbo completely and the bearings i think its called it has a little bit of move like left and right, but in and out it doesn.t have any move at all , at glow plugs i have to go to a service because i don,t want to break those
@@eduardcatalin1993 Does the engine oil smell of fuel?
@@EXOVCDShonestly i think it's smell like burn or something like that but doesn,t smell of fuel ... when this coronavirus is over i.m gonna drain the intercooler because i don t think the previous owner did that at all but what do i do with the oile from the intercooler do i get rid of it ?
@@eduardcatalin1993 It probably won't be much oil, so you can soak it up with a rag and then toss the rag in a fire pit. If it's more than 250ml, you can remove the oil filler cap and pour it in there. I asked about fuel smell because a leaky injector or injector o-ring can cause diesel to leak into the oil. The reason it does not smoke when you are driving, is because the engine has boost when "driving". Boost = more air... more air helps stuff burn better. At least that's my guess as to why you don't see the smoke when driving. Also, the smoke disappears quicker when you are driving (mixes with rushing air from around the car). The engine would have to smoke very much, for you to see it while driving.
Thank you for your video.
Thank you for watching!
What mileage is this vehicle ?
130k km's
@@EXOVCDS hi sir,
Thanks for helping on my immobilizer issue. Worked just how you said it would.
Another issue is exactly what you speak of in this video.
What I wanted to know was if you replace the turbo or PCV, whichever is giving the issue. Would it stop collecting oil in the intercooler or would it just be less?
@@konquerorx Less... there will always be PCV fumes / oil in the Intercooler as long as PCV is vented into the turbo inlet.
This EGR valve housing probably never has been cleaned from purchasing the car.
Possibly... first time customer.
They need a sensor for that. Oh, they got you. 😂😂
Hehe!
Cant say I have seen that much build up before! Damn.
I've drained more from others... definitely something that should be checked at every oil change!
right in the face, that's what she said!😅
LOL!!!
no need to try this hard.
use liqui moly
Liqui moly what? Oil? Fuel Additive? Oil additive?
None. All great products. But the only way to eliminate oil in the intercooler and charge pipes is with a catch can
LOL
Keep ehr dirty buddy!
I clean my cooler with washer fluid.
th-cam.com/video/kY-2HRUdaqQ/w-d-xo.html
@@EXOVCDS i jus saw dat, happy it was found out (feelings, they are so strange and dang accurate sometimes) and that it did not cuse more stress!