Izzy you have a PM.
Clay, 99% of the work is completed.
Going to the alignment shop this morning.
When I get it back all I have to do is the alternator booster wire.

 

No problem.

 

Dan, how do you go about cleaning the intake manifold?
The right way to clean a ALH TDI intake manifold - YouTube

 

Wow, that stuff was flying pretty far at times... wonder how much landed on the car.

 

He's doing it wrong.
You're supposed to soak them in solvent first, then apply heat to the intake part, then blow the compressed air in that way.

 

haha, awesome! what do you do for a final clean?

 

Drop it in a bucket of water.
Leaves a small amount stuck to the walls, but no build up.
Blast it with compressed air and good to go.

 

Pardon my ignorance...Is the alternator booster wire a known defect fix like a Hutch mod (for example), or is it specific to Clay's car? Thanks!

 

A LOT of car designs design the charge circuit with "just enough" capacity in the wiring system to do the job - no more.
The end result of that short sightedness is a dead battery after driving in heavy traffic with all the accessories turned on.
Heavy traffic = low engine rpm, lousy weather = heater on, rear defog on, headlights on, seat warmers on = battery slowly gets drained out because the charge circuit cannot keep up.
Putting a large cable between the alternator output post and the battery positive post cures that every time.
Been doing that trick for about 25 years now and I've NEVER had a comeback with a dead battery after installing something like that.

Here is how I did it on my F550.
Use 6g minimum with 4g being fully adequite for the task.

 

Clay, I'm finishing up with your car.
I'll have it ready to pick up before I go home tonight.
Call me in the morning and I will meet you here at the shop with Ed whenever you want.

 

All done.
See you tomorrow.

 

Very nice!

I want one in dark grey!

Stewart

 

Clay, I'm jealous, yours has way more power than mine for some reason!!!

 

Clay great find. And to just be by a great mechanic, double great find. Nice job Dan, now find me one.
Chet

 

Looks awesome! Will be good to see you and Ed again. It's been to long.

If I had my choice that's the only thing I would change about it but they are so hard to find it wasn't worth passing on.

Sweet! That's not usually my kind of luck

We are very blessed to have Dan for both his VW and Powerstroke knowledge. Reps to to him for going the extra mile.