Hey Dan,
How does the intake get so plugged with soot? Just poor maintenance?

Clay, Throw away that Chiltons manual and get yourself a Robert Bentley in stead!


My 1981 Rabbit pickup 1.9 n/a diesel still gets 42 MPG after 200k miles on the truck. Just glad I'm not in hurry!
Nick

 

You couldn't give me a Chiltons I am not sure where the one in the pic came from. I haven't even seen the car in person yet.
I am not getting this to work on it anyway. Hence the reason Dan has it

 

And of course, given the vehicle, it couldn't be in better hands.

Is this a new DD for you, or is it for Kristen?

Pop

 

Kerma is teamed with Pete, I'd just go through Pete directly if that is the service you choose. PPs or Titans are probably a better choice over the sprints from a quality standpoint.

 

The TDI has the 6.0 disease: an EGR valve, so all that soot gets accumulated over time.
The EGR valve combined with the oil mist from the crankcase breather makes the all that buildup happen over time.
I'm doing a CCV mod for Clay so that will cut way down on the buildup.
If I disable the EGR then the check engine light will come on, so the CCV mod is a good way to eliminate this problem.

I posted some new pictures from yesterday.
Teflon coated 100,000 mile timing belt, changing injector nozzles, and various shots of the engine in different states of dissassembly.
Finishing everything up today and taking the car down to the alignment shop tomorrow.
Click on the picture and you can see the rest of the photos.

 

Good going Dan. How about a pic of that thing doing a burnout?

 

Dan, would you recommend the CCV mod on a 2011? There's very little info online about the new TDI's. Also, I was told by the dealer that the timing belt interval has been upped to 120,000mi, what's your take on this?

 

Nice try.

I thought they were chains now.
I'll have to look into that.
If it's still a belt, I wouldn't go past 80k.
Just had a customer come in last month with 90k on his original belt and it failed, ruining the motor just like that one I posted about on Facebook.
He didn't have the money to fix that one so he had it towed home for now.
For my own vehicles, just to be safe, I do them every 50k, but that might be a little overkill.
On my own TDI I've racked up 30k so far since I did mine and plan on changing it out at 50. Just the belt this time around, all the rollers should be good.
The next time, if I still have the car, it will be a complete job like I'm doing for Clay right now..

.
Ok, back to work. Need to finish up Clay's car for Saturday delivery.

 

NICE! I was hoping they would do something about that. I was picking brains at the dealership when I was getting the car and the guys there couldn't answer any of my questions.

 

Here's the CR timing belt kit: Timing Belt Kit (CBEA CJAA) - IDParts.com

 

Looks like I have a long future ahead of me doing timing belts.
I really thought they were timing chains by now.

Taking a quick dinner break, got the engine running, still need to set the pump timing.
You can see the CCV mod that I put in about halfway through going up over the intake.

ClayJettaTDI.MOV - YouTube

 

Dont forget you got a TDI specialist down here in socal.
Dan, The current TDI still sports a timing belt and in my opinion is even easier than an ALH motor belt. You dont even need to loosen the engine mount. As far as modding a 09 and up I would not recommend doing anything to them other than a ecm reflash ( I have a neuspeed flash in mine that is suppose to add about 25hp). As far as the soot/gunk in the older tdi's it seems to happen more when people drive them around town for short distances and never drive them for a long distance or past 1/4 throttle.

 

Sounds and looks great!

 

Thanks Carlos. You might be hearing from me if I have a question some day.

 

I'd like to add to this if you don't mind and state that I agree with Dan. The 1.8l turbo sitting in my driveway smoked the timing belt 2k miles past warranty, granted it's not diesel but an interference motor none the less. It's the first foreign front drive vehicle to ever be parked on my property so I didn't know any better at the time... though I should have. Even though I did all the work myself, all the parts added up to a huge chunk of change. Enough that I could have done some major mods to the Powerstroke. Needless to say, it gets changed every 50k now.