Today I.....

Worked a overtime shift to fund my habit (buying car parts for what i consider bargain prices)
Refitted my 5 seater rear bench, crickey it needed a almighty effort to get the back rest back up from its locked position to the base!
Anyone removed inlet manifold from a AMF, fancy giving mine a clean?
 
Howey said:
Worked a overtime shift to fund my habit (buying car parts for what i consider bargain prices)
Refitted my 5 seater rear bench, crickey it needed a almighty effort to get the back rest back up from its locked position to the base!
Anyone removed inlet manifold from a AMF, fancy giving mine a clean?
Click to expand...
Mister muscle is your friend to remove the internal muck followed by jet wash then brake & clutch cleaner to finish, its time consuming & messy but worth it!
Appropriate personal protection is necessary due to products in use!!!
Hth
Keith
 
kp 115 said:
Mister muscle is your friend to remove the internal muck followed by jet wash then brake & clutch cleaner to finish, its time consuming & messy but worth it!
Appropriate personal protection is necessary due to products in use!!!
Hth
Keith
Click to expand...
What access like to remove it?
Did my galaxy 1.9 tdi pd other day access wasnt bad but a little tricky due egr cooler!
Cheers for that heard mr muscle was a great tool for the job!
 
]
Howey said:
What access like to remove it?
Did my galaxy 1.9 tdi pd other day access wasnt bad but a little tricky due egr cooler!
Cheers for that heard mr muscle was a great tool for the job!
Click to expand...

Funnily enough, I've got to do my EGR (AMF like yours), had a quick look thinking access would be nice and easy (as per my Passat 130) but was surprised how tucked away it was. Turned round, left garage and toasted hot crossed buns instead. Car's performance appears unchanged.

Anyway, tips on removal also appreciated: does the vent cowl thingy come off to gain access?
 
By all means clean up the valve, but fit a blanking plate, or a 6mm stud to the connecting pipe. This disables the valve, and stops muck recirculating!

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Howey said:
What access like to remove it?
Did my galaxy 1.9 tdi pd other day access wasnt bad but a little tricky due egr cooler!
Cheers for that heard mr muscle was a great tool for the job!
Click to expand...
I suppose it depends on what else you’ve got removed, mine was due to a cambelt failure
so I removed head to check for damage
so turbo & exhaust was off as well, but I lowered the engine to gain access to timing belt etc, whilst you in there I highly recommended checking the operation of the
integral dump valve in the exhaust manifold as mine was virtually seized, so I lapped the faces in & freed off the operating linkage & lubricated with copper slip , followed by new vacuum & air hoses whilst in the to give another 200,000 miles.
Hth
Keith
 
Rusty911 said:
]


Funnily enough, I've got to do my EGR (AMF like yours), had a quick look thinking access would be nice and easy (as per my Passat 130) but was surprised how tucked away it was. Turned round, left garage and toasted hot crossed buns instead. Car's performance appears unchanged.

Anyway, tips on removal also appreciated: does the vent cowl thingy come off to gain access?
Click to expand...
Yes it’s attached under the scuttle cowelling
2 screws if I recollect
 
I can remove the egr without taking the air intake off
A CB long series Allen key is a must
The worst is the removal of the two Allen bolts holding the exhaust input to the egr
I cut off about ½” off the short leg on an Allen key to get access but it’s still tight access and a flat at a time normally after a turn it will come out with fingers then repeat for the other bolt
Audi fitted a bloody bracket in the way to make matters even more difficult

I’ve done a few and can swap on out and new one in in just over an hour now

Paul


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depronman said:
I can remove the egr without taking the air intake off
A CB long series Allen key is a must
The worst is the removal of the two Allen bolts holding the exhaust input to the egr
I cut off about ½” off the short leg on an Allen key to get access but it’s still tight access and a flat at a time normally after a turn it will come out with fingers then repeat for the other bolt
Audi fitted a bloody bracket in the way to make matters even more difficult

I’ve done a few and can swap on out and new one in in just over an hour now

Paul


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Click to expand...
Does that mean that the air intake is a pig to remove?
 
There are a few thing to remove to access the bolt eg wiper arm and scuttle trim which is fragile


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depronman said:
There are a few thing to remove to access the bolt eg wiper arm and scuttle trim which is fragile


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Click to expand...
I would go with all that Paul has said , the EGR is a battle to get out 1st time around , there is a nasty little bracket at the back of the engine which really gets in the way ..

However, attracting a Allen key 6mm with a angle grinder , and looping of the end gives the required clearance to crack the bolts , i refitted those using a bolt which takes a 6mm head , adding loads of copper grease ...

You can see how much you need to remove in
photos

The last photo shows the nasty bracket , and how to gain access , I removed the air duct , and the vacuum hose from the fuel pump
You can also see how much tar had built up , and how much stuff Paul machines out with the modifications on the EGR

I have fitted the cleaned up EGR To the BHC tdi , and the modified to the ATL , I also removed a lot of the casting marks , and lumps and bumps inside the casing
Not had chance to drive the ATL yet ,but just cleaning up the one the BHC , feels like it got a further 5-10bhp , the ATL was clean to start off with so not sure what the results will be !
Time wise , 1st was a good couple of hours , 2nd time around , would say 2 hours tops


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image.jpg
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Haven’t got a TDi here to look at at the moment but I’m not sure the bracket actually serves a purpose. Perhaps one for the angle grinder/hacksaw to remove?
 
A2Steve said:
Haven’t got a TDi here to look at at the moment but I’m not sure the bracket actually serves a purpose. Perhaps one for the angle grinder/hacksaw to remove?
Click to expand...
Hi Steve,
Photo looks to be an attachment point for the engine hoist!
So may not be best to grind off as maybe needed at some point.
Hth
Keith
 
You are right it is there to aid lifting the cylinder head
Getting to it with an angle grinder would be a struggle
Mr Audi had a sense of humour when he fitted that bracket there it gets right in the way of egr removal

Paul


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Finished my A2’s suspension overhaul today new B4’s all round
Dust covers finally arrived for the front ball joints so had to go back to the front after finishing the back end off. Also cleaned up the drums and rust proofed them and painted with high temp black paint adjusted shoes at the same time so handbrake is back to one click again
Took it for run round the block and must say the pot holes are now more like ripples in the roads and the JDD box is a joy to use

The gear change is so much more positive and the ratios seem long but not overly long. 30mph is 3rd. 40 mph in 4th 50 to 55 for 5th
I only got to 60 for about ½ a mile but to took 5th at 50 and accelerated ok to 60 in5th gear on level ground
The gap between 4th and long 5th is no longer there which seems some what strange but I will get used to it
I think 5th will be a year used only on A roads and motorways possibly the odd B road but the 1st to 4th seem perfectly suited to the town and urban driving use

The clutch is so light it’s a joy to use. I guess the springs work harden over time and use

Cheers. Paul


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Away with the fairys said:
I would go with all that Paul has said , the EGR is a battle to get out 1st time around , there is a nasty little bracket at the back of the engine which really gets in the way ..

However, attracting a Allen key 6mm with a angle grinder , and looping of the end gives the required clearance to crack the bolts , i refitted those using a bolt which takes a 6mm head , adding loads of copper grease ...

You can see how much you need to remove in
photos

The last photo shows the nasty bracket , and how to gain access , I removed the air duct , and the vacuum hose from the fuel pump
You can also see how much tar had built up , and how much stuff Paul machines out with the modifications on the EGR

I have fitted the cleaned up EGR To the BHC tdi , and the modified to the ATL , I also removed a lot of the casting marks , and lumps and bumps inside the casing
Not had chance to drive the ATL yet ,but just cleaning up the one the BHC , feels like it got a further 5-10bhp , the ATL was clean to start off with so not sure what the results will be !
Time wise , 1st was a good couple of hours , 2nd time around , would say 2 hours tops


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Click to expand...
Ohhhh that looks like a pig of a job! I’d like to give it a go though, I’m sure mine is pretty bunged up. Is it 6mm Allen bolts all round? How long (or short!) did your Allen key end up?
 
Yes 6mm Allen key
I took most of the short leg away leaving just enough length to fit the socket screw
Keep it cool when using the angle grinder as you want to retain the temper in the steel

Paul


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Silverpig said:
Ohhhh that looks like a pig of a job! I’d like to give it a go though, I’m sure mine is pretty bunged up. Is it 6mm Allen bolts all round? How long (or short!) did your Allen key end up?
Click to expand...

Remind me, what engine have you got?

I've just done my AMF one: took a leisurely afternoon. I took some photo's of how I tackled the fixings.
 
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