[Vwdiesel] 120000 mile service on my Jetta/ Needs for my Sciroccoturbodiesel swap

James Hansen jhsg at sasktel.net
Mon Sep 6 03:33:11 EDT 2004

Had the same experience here Hayden, I was shocked just how much crud the
intake in the 97 Passat had.  What was even more amazing, it was running
just fine and getting normal mileage more or less.  Same deal, tiny little
holes left for the air to flow through.   I took 2 cupfuls of crap out
before solvent cleaning.
One question Hayden, since the manifold was relatively clean this time, is
the egr operating normally or just within normal parameters at a low duty

Paul, I just used scrapers, bits of stiff wire, screwdrivers, lots of light
and small mirrors.  I would be VERY hestitant to bead blast, as you can't
see the entire inside of the manifold, which means you can't directly blast
it all either, and if you leave a hidden island of sticky goo, it can hold a
tremendous amount of engine killing silica.  Stiff wire, like you find on 5
gallon pail handles is pretty good, you can bend it to shape and it holds
well enough to be a scraper to get around to the blind spots.  After the
majority of goo is scraped out, let it soak in solvent, then repeat the
scraping bit, then soak, repeat as necessary....  small crankshaft oil
gallery cleaning wire brushes held with needle nose vice grips work well
too. used carb cleaner for the final cleaning. Oh, and some good nitrile
gloves. Save your liver for other stuff that is more fun.

-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com]On
Behalf Of Hayden Chasteen
Sent: Saturday, September 04, 2004 7:54 PM
To: vW-TDI at yahoogroups.com; audi-VW-Diesels at yahoogroups.com; VW diesel
mail list
Subject: [Vwdiesel] 120000 mile service on my Jetta/ Needs for my
Sciroccoturbodiesel swap

I am rapidly approaching the 120000 mile service - timing belt, other
belts, water pump (maybe).  Anyway I have begun to do a few things like
I finally removed the intercooler and cleaned it.  Pretty messy but not
apparent standing oil.  Today I removed the intake manifold to clean it
for the second time.  When I bought the car, it had 63000 miles on it
with unknown oil use to that point so I pulled the manifold and found
it almost totally clogged.  The intake runners were closed down to
about 1/4 of their original opening size.  I immediately switched to
Mobil Delvac 1 and started using biodiesel in varying amounts.  Anyway
today I was pleasantly surprised to find only a thin coating of soot
and oil in the manifold.  The heaviest build up was found right at the
EGR valve.  Interestingly, the biggest build up was on the outside of
the valve where the pipe from the exhaust cooler connects to the
manifold.  It had a full 1/2" of hardened soot in it.  Whole job took
about 2 hours and I immediately took the car out for a run to my
property out in the country (100 mile round trip).  Car ran smooth and
nice.  When I finally reach 120000 then I will do the belts and reset
the timing.  The last time I checked with the VAGCOM, I was running a
bit retarded.  Good for NOx with biodiesel but it hurts performance a

As I begin work on the turbo engine that I am putting in the Scirocco I
realize that I need a couple of things:  a cold start cable and knob
and a mount for a alternator only set up.  There will be no AC on this
car for the time being.  I have a complete set up for power steering:
pulleys, brackets and even a pump (don't know if it is any good).  If
anybody has either of these things feel free to drop me and email.
thanks, hayden

Visit my website at  www.home.earthlink.net/~dieseltdi
Proud owner of:
2004 Passat TDI GLS, 2.0l, 8 valve, 134 HP, 247 lb/ft of torque, Blue
Graphite, Anthracite leather interior, ABS, ESP.
1998 Jetta TDI (Wetterauer Chipset, 2 1/2" exhaust, K&N Filter, 116K+
miles, and running biodiesel)
1981 Rabbit Pickup ( with a freshly rebuilt turbo engine, 7K+ on engine
now), burns biodiesel and a WVO system is in the works.
1981 Scirocco awaiting a turbodiesel transplant.
One, yet to be finished, Caddy trailer (the back end of the truck that
gave its life to my just completed Rabbit Pickup).
And many, many, many VWs; from a 1946 Beetle (11 Beetles total), to
Vans (5), Rabbits (3), Karmen Ghia (1), Jettas (5), Passat (1), Dasher
(1), New Beetle (1), and Rabbit Pickups (3) most now gone but not

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