1.9TDI FR 150 Emissions Test MoT Fail Advice

[iammooks]

Took a look at the EGR just now and it's looking like this. Not too bad but it could probably do with a clean.

Need to get a new socket set for this one - my Allen keys just don't have the right sort of reach.

It feels like the bolts aren't the same on the underside as they are on the top?

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[Nam-uk]

Mine was not that caked up when I took mine off a while ago but I still used wynns egr cleaner, that’s very strong stuff oh and don’t drop the egr gasket in the engine bay lol, all 3 fixings were same size as well.

 

[iammooks]

Mine was not that caked up when I took mine off a while ago but I still used wynns egr cleaner, that’s very strong stuff oh and don’t drop the egr gasket in the engine bay lol, all 3 fixings were same size as well.

I may* have dropped an Allen key in the engine bay while trying to get one of the bolts on the underside off.

Sounds like it fell all the way through onto the undertray, so it'll probably just fall out while I'm driving.

I've just bought a 1/4" socket set to get at the awkward bolts. It looks like the bolts on top are 5mm and the ones underneath are 6mm, because of course they are.

The gunk isn't as bad as I thought it would be, but I've had a stutter for a while and cleaning the MAF sensor didn't do anything, so fingers crossed it's that.

The hardest part is I'm working nights right now and I'm knackered trying to do all this when I've only had about 6hrs of rubbish sleep.

*definitely


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[Nam-uk]

I’ve got a magnet graber and claw grabber there not dear also seen them in pound land, really handy tool.
I’ve never cleaned mag as that can cause more issues but I’ve seen mad sensor cleaning spray for sale.
Yea the bottom fixing is awkward to say the least.
When I put the fixings back I put copper grease on the threads.

 

[iammooks]

I’ve got a magnet graber and claw grabber there not dear also seen them in pound land, really handy tool.
I’ve never cleaned mag as that can cause more issues but I’ve seen mad sensor cleaning spray for sale.
Yea the bottom fixing is awkward to say the least.
When I put the fixings back I put copper grease on the threads.

Drove to my girlfriend's place and the engine didn't blow up, so I guess I've just lost an Allen key. That or I'll find it floating around on the undertray when I next change my oil.

I'll have to get out when the weather is good to have another go at getting the EGR out.

I used the Halfords Electrical Contact Cleaner on the MAF sensor, which was about half the price of the dedicated ones. It didn't leave any residue or make things any worse at least...


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[Nam-uk]

I’ve got holts contact cleaner but I didn’t know you can use it on the maf

 

[Andrewwright]

Took a look at the EGR just now and it's looking like this. Not too bad but it could probably do with a clean.

Need to get a new socket set for this one - my Allen keys just don't have the right sort of reach.

It feels like the bolts aren't the same on the underside as they are on the top?

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You show me yours....

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[iammooks]

You show me yours....

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Holy shitballs...


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[Andrewwright]

Holy shitballs...


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I'd be careful with what you do now. Keep digging and your going to have to do what I'm going to do...head off, lots of money for an old car. Cost to sort this is nearly twice what I've paid for the thing. £600 ish ATM....time will tell the true cost.

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[iammooks]

I'd be careful with what you do now. Keep digging and your going to have to do what I'm going to do...head off, lots of money for an old car. Cost to sort this is nearly twice what I've paid for the thing. £600 ish ATM....time will tell the true cost.

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That sounds like me - I'll start with the EGR, and before I know it, the engine will be stripped down and I won't stop until every speck of soot is gone.

I'm going to try and stop at the inlet manifold. At least I'll have to, given I've got tyres being fitted on Tuesday and the retest on Thursday.


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[BigJase88]

Take it to a different MOT place diesels of that age don’t get those tests

i’ve had donkey derv 1.9’s spitting out huge amounts of black reek running big turbo’s and never failed

 

[BigJase88]

https://www.gov.uk/government/publi...or-mot-testers/diesel-vehicle-emission-limits

For a turbo diesel before 2008 the limit is 3m-1

unless you have a plate value so check that first

 

[iammooks]

https://www.gov.uk/government/publi...or-mot-testers/diesel-vehicle-emission-limits

For a turbo diesel before 2008 the limit is 3m-1

unless you have a plate value so check that first

I've been getting loads of mixed/confusing messages since they introduced the new emissions standards - some say there isn't a limit, or it's really high, while both test centres I've been to over the past two years (since they came in) used a plated value of 0.7.

In the end, I'd actually prefer that the emissions are low - less harm to the environment etc. and if I can get the engine as efficient as possible, that has to be a good thing.

Will probably try taking the EGR out tomorrow for a clean and if all else fails, will try the Wynn EGR cleaner spray.

 

[Nam-uk]

make sure you use gloves if you use it as its stong and will melt all that crap off, its like carb cleaner but hell of allot stronger, it never cleaned the EGR to Andrewwright extent but it did the job as the flap closed flush, oh i never touched the manifold ect that was as far as i went, also do you have a cat or did you take it out as that could be clogged

 

[BigJase88]

Check for any boost leaks on the intercooler pipework as a boost leak can throw out a lot of black reek which i would imagine would effect emissions

 

[iammooks]

Had a massive 'f**k this s**t' moment when I was trying to get to the third bolt and decided just to go to Halfords and get some EGR cleaner.

If I could take out the brake fluid reservoir, it would be a lot more straightforward, but at it is I'd need three very tiny hands, and my hands are pretty skinny to begin with. I'm tired, and when I'm tired I make mistakes, and I've no intention of dropping bolts and ratchets in the engine bay and having to jack the car up and take off the undertray to retrieve them.

I've heard that as you bypass the MAF to spray the EGR cleaner, you sometimes get an engine light. Is there any way I can avoid that?


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[Andrewwright]

Had a massive 'f**k this s**t' moment when I was trying to get to the third bolt and decided just to go to Halfords and get some EGR cleaner.

If I could take out the brake fluid reservoir, it would be a lot more straightforward, but at it is I'd need three very tiny hands, and my hands are pretty skinny to begin with. I'm tired, and when I'm tired I make mistakes, and I've no intention of dropping bolts and ratchets in the engine bay and having to jack the car up and take off the undertray to retrieve them.

I've heard that as you bypass the MAF to spray the EGR cleaner, you sometimes get an engine light. Is there any way I can avoid that?


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EML will come on if you unplug the MAF, plug it back in and it should go away without a code reader/scanner. Does with the 1.8t so I'd assume it does with the 1.9tdi.
If you look back on my post in "what have you done to your car today" thread I think it's called I wanted to set the thing alight and I wasn't kidding. Thing that keeps pushing me with this MK1 Leon is the fact it's a MK1 Leon....other than this car I'm off to BMW land and I'm not going 1.6 and I don't want to pay £300+ a year just to tax a 1.8t....so I've got to get use to the TDI...now the egr cooler is out it's far better to work on. Now it's like a 1.8t for ease to get to stuff.
Did think about 1.6 Leon with engine swap but the issues that come with that was silly so TDI it is.

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[iammooks]

EML will come on if you unplug the MAF, plug it back in and it should go away without a code reader/scanner. Does with the 1.8t so I'd assume it does with the 1.9tdi.
If you look back on my post in "what have you done to your car today" thread I think it's called I wanted to set the thing alight and I wasn't kidding. Thing that keeps pushing me with this MK1 Leon is the fact it's a MK1 Leon....other than this car I'm off to BMW land and I'm not going 1.6 and I don't want to pay £300+ a year just to tax a 1.8t....so I've got to get use to the TDI...now the egr cooler is out it's far better to work on. Now it's like a 1.8t for ease to get to stuff.
Did think about 1.6 Leon with engine swap but the issues that come with that was silly so TDI it is.

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Every bolt I loosened, in the back of my mind I was thinking that if I took any of them out, it was going to be hell to get them back in - especially when I might end up dropping them, or them not threading properly. OK, so if I got it out it'd be happy days, but I'd have to get it all back in again too.

Maybe when I've got nothing to do for a few days and don't have a retest hanging over me.

I will have a look at the EGR tomorrow though, just to see if the Wynn's did anything. I was going to spray it tomorrow, but the car was warm and I was at a loose end. Unplugged the MAF before I took the air intake pipe out and I didn't get any engine lights either when I was spraying it or when I plugged it back in after.

I have no idea if it runs better - it felt the same as when you take the car out after you've waxed it and vacuumed the carpets. I'll post a photo of the throttle body tomorrow.


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[Andrewwright]

Every bolt I loosened, in the back of my mind I was thinking that if I took any of them out, it was going to be hell to get them back in - especially when I might end up dropping them, or them not threading properly. OK, so if I got it out it'd be happy days, but I'd have to get it all back in again too.

Maybe when I've got nothing to do for a few days and don't have a retest hanging over me.

I will have a look at the EGR tomorrow though, just to see if the Wynn's did anything. I was going to spray it tomorrow, but the car was warm and I was at a loose end. Unplugged the MAF before I took the air intake pipe out and I didn't get any engine lights either when I was spraying it or when I plugged it back in after.

I have no idea if it runs better - it felt the same as when you take the car out after you've waxed it and vacuumed the carpets. I'll post a photo of the throttle body tomorrow.


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Not sure where your going to spray this stuff but wouldn't it dislodged what's in and around the egr and intake manifold?
Wouldn't that be very very bad? If it was me I wouldn't even beat on that engine till it's cleaned out.
I know what bolt your on about...the bottom one?
If you undo the egr cooler pipe connected to the egr you can move it about enough to get to the bolt. I just an Allen key and a lot of swearing to find the bolt was hand tight! This was the point no return when I see the state of the intake. About a month later and I'm still annoying the other half and taking her BM to work hahaha. I should post the text's I get from her when she goes out side....would probably be banned for the language used.

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[iammooks]

Not sure where your going to spray this stuff but wouldn't it dislodged what's in and around the egr and intake manifold?
Wouldn't that be very very bad? If it was me I wouldn't even beat on that engine till it's cleaned out.
I know what bolt your on about...the bottom one?
If you undo the egr cooler pipe connected to the egr you can move it about enough to get to the bolt. I just an Allen key and a lot of swearing to find the bolt was hand tight! This was the point no return when I see the state of the intake. About a month later and I'm still annoying the other half and taking her BM to work hahaha. I should post the text's I get from her when she goes out side....would probably be banned for the language used.

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I think the spray is supposed to be the lazy person's equivalent of what you've done - just not as thorough. I watched a few videos last night and did what they showed, and the same things happened, so I'm guessing I haven't done anything 'bad'. We'll see what happens...

I was looking at the cooling pipe and actually undid those two bolts, but you're right about that third bolt. There's one bolt that literally blocks the other bolt, and then you can't even get in to loosen the other one. Who the hell designed this thing? OK, so the engine bay isn't huge, but you can surely make it a little easier?

My other half doesn't have a car, so instead she has to put up with me going on about all the little things I have to do. She was sat in the car today while I was doing the EGR cleaner. She was thrilled.


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