3.0 TDI Intake Manifold Clean & Engine Valley Seal Replacement [2013 Porsche Cayenne 958] V6 Diesel
In this video, I move on from investigating the engine valley coolant leak to actually reassembling it with new parts. As part of this process, I replaced all the seals and cleaned out the dirty intake manifold.
Here are the tools I used in this video:
Oven Cleaner: https://ebay.us/RKM01l
Torx Sockets (you'll use the T30 a lot): https://ebay.us/xmnJdi
Long Torx Bits: https://ebay.us/TJ9C3I
Torx Screwdrivers: https://ebay.us/3gTd4B
Spline Drive Sockets (triple square): https://ebay.us/jGRBND
Allen Keys (you'll need the 5mm): https://ebay.us/896VDZ
Wet/Dry Shop Vac: https://ebay.us/k8YHyV
Mechanics Mirror: https://ebay.us/XQRbqI
27mm Deep Socket (for the fuel pressure sensor): https://ebay.us/i5YJ4F
And here are the parts you need to do this job:
EGR Cooler Intermediate Flange: https://ebay.us/nzWQvA
Oil Cooler Gasket Upper: https://ebay.us/q08wxp
Oil Cooler Gasket Lower: https://ebay.us/B94hkI
Intake Manifold Gasket Set: https://ebay.us/E5elGN
Intake Throttle Pipe Gasket: https://ebay.us/2hQafQ
Throttle Body Seal: https://ebay.us/EVzpki
Intake Manifold Gasket: https://ebay.us/tU2LAO
The good news in the previous video was the clear problem I had with the EGR cooler intermediate flange that had obviously been broken for some time. I got a new one of these along with new seals for the oil cooler base plate and oil cooler.
It's also strongly recommended to replace all of the intake seals between the first throttle body and the intake manifold where it meets the head of the engine as they are known to stiffen with time and cause air leaks - leading to poor running.
As I discovered in disassembly, my intake manifold was unbelievably dirty and clogged thick with oily soot. I would bet this has never been cleaned out in the 10 years and 130k miles of life this TDI engine has had.
Unfortunately, this is the nature of modern diesel engines, and while I recently commented on how how clean the exhaust looks, its clear to see where all of the diesel emissions are going - back into the intake.
The mixture of soot and oil is a remarkably stubborn mess to to clean up. I started off by using dish soap and hot water, which merely spread the black gunk around into an even worse mess.
I went on to clean the throttle body with white spirit, which worked albeit slowly. From some research, I discovered that oven cleaner is effective at removing it, which would make sense as the deposits in your oven are vaguely similar in contents.
With three cans of Dr Magic Oven Cleaner, I we set about cleaning out the intake of this V6 TDI motor. The best method is to scrape as much of the gunk out dry as possible, then spray in the oven cleaner and allow it to dwell for 30 mins or more, then rinse.
You may want to repeat this a few times to get a good result. I was happy with the outcome although it took around half a day in the end.
I then put the whole engine bay back together and torqued up all of the screws correctly to 9nm. It's challenging to get the intake manifold back on, but with patience, you will get there in the end.
Once everything was back together I topped up the oil and coolant and pressed the Cayenne back into daily duties.
This was going extremely well and the car feels more responsive and maybe even faster following cleaning out the intake. I suspect the adaptations were resetting which made it feel a bit peculiar for a while.
Sadly, by the end of the week I was seeing "Check Coolant Level" warnings on the dash again which was heart breaking. In the video you will see I confirm that my engine valley coolant leak is still ongoing and I'll need to put more time into solving it.
A real shame but at least now I know how it goes together.
For more helpful how-to guides and restoration project logs, visit our blog: https://www.spannerrash.com/
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