Noisy 1.9tdi Mk1

[daran71]

Hi - My old gal has been giving me a real headache over the last couple of weeks!!! Started off with a noise when accelerating - diagnosed by anyone who heard it as blowing somewhere at or near the manifold.

 

After an initial inspection I found he egr pipe was split in half and replaced it - still not quieter!!

 

SO got it up on ramps yesterday at a well known local exhaust company and they said it looked from what they could see leaking from the manifold. So i tried to feel for leaks and found 2 bolts loose - finger tight only on the manifold. So stripped out all sorts of plasic air pipes to get access and nipped them back up but still getting this horrible rattling noise on acceleration. It idles lovely and doesnt particularly rattle when reving in neutral but when driving it rattles as you accelerate - so im guessing the pressure is higher hence the noise.

 

As it was still noisy i made up a spray bottle of washing up liquid and found some bubbles appear around the gasket at the bottom studs side of the egr pipe - I refitted the egr pipe using instant gasket in addition to the metal gasket and that seems to have sealed it but the noise remains?

 

Now comes the hard bit to explain!!! So please bare with me........ if i am looking at the rocker cover - directly behind is the manifold on top of this is the egr valve - the egr pipe comes out from the right hand side and then drops down to a flange fitting with 2 studs that you put nuts on. Well this bit that it bolts to is either a part of the engine or is another part bolted to the side of the engine - its hard to see - even with a mirror!! Either way I can feel a leak here. Ideally I would like to see an exploded diagram of the whole assembley here or some good photos ?

 

Also i went to the motor factors to get replacement gaskets for the manifold but they said intake or exhaust manifold? I thought manifold with the egr on top was the exhaust manifold but im guessing that is known as the intake manifold? Am i right?

 

thanks for looking at another of my long winded and not very technical questions!!!

[daran71]

Just an update - problem solved!!

 

After doing some more reading to find out what all the parts at then back of the engine are called I decided to change the exhaust and air intake manifold gaskets. After removing the intake mainfold i checked all the nuts on teh exhaust manifold and found them all to be loose. I tightened them all up and then cleaned out the intake maifold and fitted a new gasket. After re-assembling all the sundry parts that I had to remove to get to it all it is now running very nicely - quieter - just like a normal diesel engine and distinctly more power. I still have the vacuum hoses to change but the difference so far is vast!!!

[lewis]

I have V6 petrol galaxy and im having a similar prob i think. I get a lot of noise when accelerating and it appears to be coming from the back of the engine somewhere. (had the exhaust checked and it was ok) So im thi nking it must around the manifold area , I know your is a diesel but any chance of a couple of pics of what u found?

Cheers Lewis

[daran71]

I have V6 petrol galaxy and im having a similar prob i think. I get a lot of noise when accelerating and it appears to be coming from the back of the engine somewhere. (had the exhaust checked and it was ok) So im thi nking it must around the manifold area , I know your is a diesel but any chance of a couple of pics of what u found?

Cheers Lewis

 

Sorry i didnt reply earlier - just seen this post!! I havent got any pics as its a tight squeeze behind the engine but i would reach behind and feel for any loose nots near the exhaust or intake manifold - make sure its been switched off for a while as it gets hot !!! If nothing have a look for black sooty deposits where burnt fuel deposits might be escaping!!