[tregbert]

Hi Tregbert, is yours a 2.5 with engine code BAC and does it half fire up when starting, then cranks over fast as if the engine has no compression? Then when it starts it releases a cloud of black smoke? If so I suspect that the manifold shut off flap is sticking shut. This flap sits just before the inlet manifold and basicly shuts off the air supply to the engine when you switch off , it then re-opens . But if it doesen't re-open the problem I describes occurs. Let me if this is your problem

Hi Touareg tech, it is that exact model with those exact symptoms is the cure to clean around the flap???

 

[tregbert]

Well the problem was sure enough a clogged up flap in what is the EGR valve assembly, i simulated the actual problem today. So i removed the housing, firstly disconnecting the main air intake duct, unbolting the exhaust bypass gas pipe, disconnecting the vacuum hoses to the EGR valve and the vacuum operated valve mounted to the side of the housing. Lastly the 4, 5mm allen key bolts which mount it to the inlet manifold were removed, BINGO assembly removed, it needed a through clean as all gunked up with a mix of EGR gases, recirculated exhaust soot & alittle oil from the turbo pipes. After cleaning it was all reassembled and the flap operated fullly and correctly without sticking, job done.
So if anyone has occasional Starting issues with a 2.5TDi then look no further.
I will add that my touareg is a low mileage 32,000 mls from new, serviced every year, regardless of my low mileage and with the Correct VW longlife oil, and it still clogged up. Its often driven enthusiastically and only uses Shell Diesel, so question begs how can this be prevented??

 

[tregbert]

Yeah as above ive removed and de coked it and superb now, thanks a million