daran71 Posted May 9, 2011 Report Posted May 9, 2011 Hi - I have the car mentioned in the title and its had a few problems lately with oil leaks - loss of power - anti roll link bars but i am stradily plodding through them to keep the old "gal" on the road!! 140,000 on the clock now, the last 40,000 put on by me in the last 3 years so im not complaining!! Anyway, took a 300 mile round trip Sunday and on the way home it started to sound like a noisy lawnmower or a tank!! I got it up on ramps today and found a couple of minor holes in the exhaust that can be repaired for now but i also found another pipe completely split in two. My trouble is im not sure what it would be called so i will describe where it is and what it looks like and see if anyone can name this part!! Ok behind the rocker cover sits the turbo - it has the plasyic air hose coming off it which goes down to the intercooler under the radiator - just behind this pipe is a metal pipe between the manifold and the turbo held on by 2 allen key bolts at the turbo and 2 nuts over studs at the manifold. It is covered with a steel mesh and the middle section of it sort of layered? Its about 10 inches in length and has a slight angle and a slight brass tint to it?? Its and airpipe of some sort? I did get one from a local breakers yard today but the pipe the bloke took off in front of me looked similar but he removed it from the left hand side whereas on my car it comes from the right of the turbo - tried to fit it but the angle was wrong for fitting it to mine!! I am going to try and ring eound the local yards tomorrow but I would like to know what its called for 2 reasons - 1. to stop me having to go through this big description again and 2. because if they think i dont know what its called the pound signs will light up and they will try and charge me a fortune!! Also as a last resort i can always go to the dealers!!! Thanks for your help!! Also does anyone know of anywhere where i can buy the braided hose that is used for the vacuum hoses off the roll?? And if so what size diameter should I be asking for?? Quote
Willie Krashitt Posted May 10, 2011 Report Posted May 10, 2011 Hi, From your description it sounds like the EGR pipe. Not familiar with Mk1's so am only guessing that it is about 25mm diameter and made of stainless steel?This bolts to the EGR valve with 2 allen bolts, and to the exhaust maniflod with 2 stud/nuts. If this is the pipe, they should cost Quote
daran71 Posted May 10, 2011 Author Report Posted May 10, 2011 Thanks George - thats a much better description than mine!! That gives me all the ammunition I need to get a replacement now!! Thanks again!! Quote
new nige Posted May 10, 2011 Report Posted May 10, 2011 I just got hoses from hose world ltd 01289 386430 via post braided rubber fuel tubing 3.5mm id x 8.5mm od and 5mm id 10mm od both about Quote
daran71 Posted May 24, 2011 Author Report Posted May 24, 2011 (edited) A quick update - Afer much fussing about i decided to change the gaskets on the exhaust and intake manifolds. I found 2 of the allen key bolts on the intake manifold loose - then every nut on the exhaust manifold was also loose. I nipped the exhaust ones back up after removing the intake manifold and egr. I also cleaned out the manifold before refitting it with a new gasket. To get to everything I removed all the air hoses and the air filter box. Now its all done the car actually sounds like a diesel engine should - no rattle at all!! I have noticed an immediate increase in power too!! I still need to change all the vacuum hoses as they are a bit worse for wear and thats a job for tomorrow, but now I have seen them up close the task is far less daunting!! Thanks for the tips!!! I also sourced a second hand egr pipe (£20) and changed that too - I used a bit of instant gasket on the bottom studs on this though as even though the gasket looked good it was still letting some air escape!! Edited May 24, 2011 by daran71 Quote
Galaxy newbie Posted May 25, 2011 Report Posted May 25, 2011 Hi mate I've got exactly the same engine as you after an engine swop, don't suppose I could get you to check your vacuum hoses from your egr solenoid and turbo solenoid on bulkhead and tell me where each one goes to as I still don't think mine are right as no turbo at all. If you would it would be a MASSIVE help. Thanks. Andy Quote
new nige Posted May 25, 2011 Report Posted May 25, 2011 Andy This diagram should sort you out same engine as me! nige Quote
Galaxy newbie Posted May 25, 2011 Report Posted May 25, 2011 (edited) Yeah saw that one nige, that's the latest one I went by but a couple of there pipes on there don't make sense. The one coming from ecu I assume goes to the intercooler to manifold pipe, is that correct? And other one I'm lost with is the one running from the single outlet on the turbo solenoid, I see 2 go to the turbo but what's the little curled pipe it points to? Also on the brake servo pipe where the 2 outlets are the diagram shows only 1 pipe connected but the other outlet on mine is hissing although I thought it was a 1 way valve?? Stumped. Also nige when the turbo comes in is the sound noticeable or not, and roughly what rpm does the turbo kick in. Sorry for all the questions. Will have the ecu how to up tomorrow. Edited May 25, 2011 by Galaxy newbie Quote
daran71 Posted May 25, 2011 Author Report Posted May 25, 2011 Hi - I am away for the weekend from tomorrow but if you can hang on until Monday I will be happy to take some pics and describe exactly where all the vac hoses run!! Quote
new nige Posted May 26, 2011 Report Posted May 26, 2011 Yeah saw that one nige, that's the latest one I went by but a couple of there pipes on there don't make sense. The one coming from ecu I assume goes to the intercooler to manifold pipe, is that correct? And other one I'm lost with is the one running from the single outlet on the turbo solenoid, I see 2 go to the turbo but what's the little curled pipe it points to? Also on the brake servo pipe where the 2 outlets are the diagram shows only 1 pipe connected but the other outlet on mine is hissing although I thought it was a 1 way valve?? Stumped. Also nige when the turbo comes in is the sound noticeable or not, and roughly what rpm does the turbo kick in. Sorry for all the questions. Will have the ecu how to up tomorrow. ECU to inlet manifold pipe yes From memory is the curly pipe not the exhust in to the turbo? I did mine by feel from the top so cant remember what it looks like Quote
Galaxy newbie Posted May 26, 2011 Report Posted May 26, 2011 What about the servo pipe that runs around the right side of engine with 2 outlets. Do you just have the 1 pipe connected to that and if so are you not getting air hissing from the other outlet next to it? Quote
chrispb123456 Posted May 26, 2011 Report Posted May 26, 2011 Yeah saw that one nige, that's the latest one I went by but a couple of there pipes on there don't make sense. The one coming from ecu I assume goes to the intercooler to manifold pipe, is that correct? And other one I'm lost with is the one running from the single outlet on the turbo solenoid, I see 2 go to the turbo but what's the little curled pipe it points to? Also on the brake servo pipe where the 2 outlets are the diagram shows only 1 pipe connected but the other outlet on mine is hissing although I thought it was a 1 way valve?? Stumped. Also nige when the turbo comes in is the sound noticeable or not, and roughly what rpm does the turbo kick in. Sorry for all the questions. Will have the ecu how to up tomorrow.Hi AndyThe large brake servo pipe with the two connections.The MK2 also has this but one is blanked off with a rubber cap (blanking plug) could be the same for yours.I suppose it could be used as a test point for use with a vacuum gauge but not seen any reference to it.Incidently the blanking plug on mine fell to pieces where it had rubbed against another pipe, I just used a short length of hose with a small bolt in the end to blank it off. Quote
Galaxy newbie Posted May 26, 2011 Report Posted May 26, 2011 Cheers Chris as without something on there I lose my braking efficiency slightly. Will do that :-) Quote
zorgman Posted May 30, 2011 Report Posted May 30, 2011 blank it off and let your engine breathe clean air, first thing i do with tdi's just make a ally plate and stick it on the exhaust side on mine its totally removed so 2 plates are needed.going to get the ""it aids cooling blah blah"" but ive got 160k on my engine and its as sweet as a nut, its a big thing in the states with quite a market for the plates Quote
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