Project 13 - 2001 VW Beetle TDI Intake Manifold and EGR Valve Cleaning

This article describes in detail how the DIY or owner of a VW Beetle can easily remove the intake manifold, and EGR valve for cleaning.


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Project 13 - 2001 VW Beetle TDI Intake Manifold and EGR Valve Cleaning

Cowling Removal

The TDI Guy is cleaning the intake manifold and EGR valve for the owner of a 2001 VW Beetle TDI. The TDI owner complained there was no acceleration when the tachometer needle reached 3000 rpm's.  The two (2) components are removed as follows:

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     A lifting device is not needed for this repair.
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     The firewall cowling has to be removed so that hoses can be removed to gain access to the intake manifold.
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     Using a scratch awl or hook pick, remove the caps to the bolts that secures the driver-side and passenger-side windshield wipers. Figure 13-1 shows the caps being removed from the passenger-side windshield wiper.

Removing Caps to Windshield Wiper

Figure 13-1 Removing Caps to Windshield Wipers

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     Using 3/8-inch square drive ratchet and 3/8-inch square drive 13mm socket remove two (2) nuts that secures the windshield wiper arms.
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     Using flexible cable hose clamp pliers, remove the air intake hose to the air filter and remove filter (Figure 13-2).


Removing Air Inlet Hose

Figure 13-2 Removing Air Intake Hose to Air Filter

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     Using flexible cable hose clamp pliers, remove the hose from the EGR valve to the intercooler pipe. (Figure 13-3)

Removing EGR hose to Intercooler

Figure 13-3 Removing Hose From EGR Valve to Intercooler

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     The firewall cowling is a cosmetic panel that is attached to the firewall.
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     Remove the cowling by pulling on the edges and pulling forward toward the front of the engine. It is a snap fit and no screws hold it intact to the firewall.
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     The firewall cowling bracket is removed using a 1/4-inch square drive ratchet and 1/4-inch square drive 10mm socket. Figure 13-4 shows one (1) of several bolts that are removed to remove the cowling bracket.

Bezel bracket being removed

Figure 13-4 Cowling Bracket Being Removed

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     Using 3/8-inch square drive ratchet and 3/8-inch square drive 6mm hex bit socket, remove two (2) bolts top (Figure 13-5) and two (2) bolts on bottom flange that secures the EGR valve to the Intake Manifold.

Remove bolts to EGR valve

Figure 13-5 Removing Bolts to EGR Valve

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     Remove two (2) bolts to the EGR cooler pipe (Figure 13-6)


Remove bolts to EGR cooler pipe


Figure 13-6 Remove Bolts to EGR Cooler Pipe

EGR Valve Removal

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     Remove the two (2) bolts on back of EGR valve that connect to EGR cooler pipe connection with a 3/8-inch square drive ratchet and 3/8-inch square drive 6mm hex socket (Figure 13-7).

Removing bolts to EGR cooler pipe

Figure 13-7 Removing Bolts Connected to EGR Cooler Pipe

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     Figure 13-8 shows the EGR valve removed from the intake manifold.

EGR valve removed from intake manifold

Figure 13-8 EGR Valve Removed From Intake Manifold

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     The EGR valve was placed in a parts washer for a bath to remove all carbon deposits and grime. Figure 13-9 shows the EGR valve placed in the parts washer.

EGR valve placed in parts washer

Figure 13-9 EGR Valve Placed in Parts Washer

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     Once placed in the parts washer, the valve was checked with a hand-held vacuum pump for rod movement. The rod membrane must move in the direction of the arrow as shown in Figure 13-9 (above) when the hand pump is operated.
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     A rod that does not move or return to its original position when the pump is removed will have to be replaced. Figure 13-10 shows the EGR valve placed in the parts washer with the hand vacuum pump hose attached to the vacuum port.

Vacuum hose of vacuum pump attached to EGR valve

Figure 13-10 Vacuum Hose of Vacuum Pump Attached to EGR Valve in Parts Washer

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     The owner of the Beetle complained of "low power". Usually, the cause is a severely clogged intake manifold or leaking vacuum lines. Figure 13-11 shows the clogged intake with the EGR valve removed.


Clogged Intake Manifold

Figure 13-11 Clogged Intake Manifold on Beetle TDI

Intake Manifold Removal

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     The intake manifold is secured to the cylinder head with six (6) bolts.
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     They are removed by feel (you cannot see them). An inspection mirror is used to locate the bolts so that they can be removed.
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     Using a 3/8-inch square drive ratchet and 3/8-inch square drive 6mm hex bit socket, loosen and remove the six (6) bolts that secures the intake to the cylinder head. Figure 13-12 shows the intake manifold removed from the cylinder head.


Intake Manifold Removed

Figure 13-12 Intake Manifold Removed

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Intake Manifold Cleaning

The TDI Guy uses a two (2) part process to clean an intake manifold. The steps for this procedure are listed below:

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      In process one (1), the dirty manifold is placed in a one (1) gallon can of Berryman Chemtool Carburetor cleaner.
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     The intake manifold is soaked in the solvent for approximately three (3) hours.
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     The intake is then removed from the solution. The excess solvent is washed off with a garden hose, soap, water, and dried with shop air and an air nozzle.
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     In process two (2), the cleaned intake is placed in a dishwasher. The timer on the control panel is set to "high temp wash". The intake manifold is sent through two (2) wash and dry cycles. Figure 13-13 shows the intake manifold that has been cleaned and ready to be installed on the Beetle TDI.


Cleaned Intake Manifold

Figure 13-13 Cleaned Beetle TDI Intake Manifold

Finishing  Up

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     A new intake manifold gasket must be obtained from a VW parts center or an Internet vendor before the cleaned intake manifold is installed on the cylinder head.
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      When installing new intake gasket, the replacement gasket coated (beaded side) faces the intake manifold.
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     The intake manifold lock bolts are torque to specification in Table 13-1.

Component
Torque Setting
Intake Manifold Lock Bolts (6) 18 ft-lb



Table 13-1 Torque Specification for Intake Manifold Lock Bolts

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     Install the EGR valve, bolts to cooler pipe, and hoses in the same order that they were removed.
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     Start the engine and check for manifold leaks.
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     Install top engine cover and hose that was previously removed.
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     Test drive vehicle.

Tools, Equipment, and Materials

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     Scratch awl or hook pick
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     3/8-inch square drive ratchet
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     13mm 3/8-inch square drive socket
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     Flexible cable hose clamp pliers
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     1/4-inch square drive ratchet
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     10mm 3/8-inch square drive socket
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     6mm hex bit socket
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     Parts washer
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     Biodegradable washer solvent
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     Hand operated vacuum pump and accessories
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     Berryman Chemtool carburetor cleaner
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     Garden hose
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     Air compressor
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     Air nozzle
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     One (1) new intake gasket
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     3/8-inch square drive torque wrench
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     Dishwasher