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Thread: 2.4 tdci EGR / Inlet Manifold clean + VCV Replacement

  1. 28th August 2016, 06:07 PM #1
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    2.4 tdci EGR / Inlet Manifold clean + VCV Replacement

    Got a few more things done to the tdci induction system today.

    When doing my BAS EGR delete a few months ago the pilot correction learn took three attempts. I had also been getting a P167B-41 (2F) injector learning not done fault. Pete Bell indicated it could be the VCV or possibly a faulty injector. I had been getting some diesel pinging but no smoke or other symptoms.

    I sourced a Denso VCV and some gaskets and went for it😬

    First up inlet manifold - fecking filthy! Only took 30min to remove
    My 2.4 is at 70k and honestly if you haven't done this seriously consider it. I think even when my old 300tdi was burning 3L of oil per 5000km it's exhaust manifold was still cleaner than this things inlet manifold.

    I followed the manual apart from I didn't remove the fuel supply line (return yes) ... Was easy enough. Inlet full of gunk cleaned it with petrol and pressure washer... Came out close enough to pristine.

    Photos of the gunk attached

    S
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  2. 28th August 2016, 06:17 PM #2
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    More pics of inlet pre clean
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  3. 28th August 2016, 06:19 PM #3
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    Final pre clean (apologies iPhone only likes one attachment at a time)
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  4. 28th August 2016, 06:26 PM #4
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    And now one post clean
    Note the two "apprentices" having smoko. ... Actually from memory they pretty much smokies the whole morning away!
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  5. 28th August 2016, 06:47 PM #5
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    Next job was changing out the VCV - with the manifold removed access is easy
    For all the tasks today a good selection of 1/4 and 3/8 drives is imperative! To be honest after today I'll be sourcing a top quality 1/4 ratchet drive. I have plenty of 1/4 sockets and extensions but my old kinchrome driver is a little chincy ... I can see 1/4 being pretty vital on this tight engine bay.

    Anyway photo showing location of VCV

    THE NEW Denso VCV came with gasket o rings and new SHCS
    Easy swapover
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  6. 28th August 2016, 06:59 PM #6
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    Finally onto the EGR
    Access is reasonable with the manifold removed but still not what you would call easy.
    1/4 drive for the win
    Despite some online instruction to access lower EGR bolts from below for mine it was easier to manipulate from above.

    Quick tip one remove EGR to inlet flange first and replace last.
    Quick tip two (probably should be mentioned earlier) the EGR electrical connector is a bit tricky, I found taking a length of no. 8 turning a 10mm radius bend in one end, grinding that turned tip to a flat could then be used to hook under the connector and release the latch.
    Quick tip three. Picture not great but where my boofy finger is pointing you can see the fuel supply line crossing the EGR ... Fuel line has Kevlar sleeve but on mine this is still a rub point. I installed some extra hose protection to stop rub through on what is a pretty important fuel line

    S
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  7. 28th August 2016, 07:06 PM #7
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    So all back together
    High pressure pump reset and pilot correction learn
    (Note that pete said to flick ECU back to standard prior to replacing VCV)
    So final move was to change up to EGR deleted ECU program

    Argh **** one last thing also on Petes recommendation when I put the EGR back on I put in a solid ie blocked gasket between cooler and EGR. So should now

    With provent in PCV system and EGR cleaned and blocked induction should be clean and stay clean.

    Last job will be to pull Intercooler clean it and replace hoses with silicone

    Maybe Tommorrow morning

    Steve
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  8. 29th August 2016, 07:00 AM #8
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    You have missed your calling..you should have been a dentist! All that delicate work in a confined space
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  9. 27th July 2022, 02:36 PM #9
    Bikini Black Guest
    Hi, newbie on this forum, I’ve registered but can’t see your pictures? Any help much appreciated as I want to do this exact procedure myself - cheers.
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