1.9TDI FR 150 Emissions Test MoT Fail Advice

Nam-uk

Active Member
May 11, 2011
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lancashire.
I've ordered a new gasket for the manifold - I don't think it'll be up to much after 160k, but all the stuff I've taken off so far looks like it's in good condition.

I just came by a video where they filled the manifold with Mr Muscle and then used a jet wash to clean out the muck. That's more or less what I had in mind, so I must be on the right track.

I'm hoping after all this effort it's actually going to make a difference to performance...


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is the egr gasket ok? There not dear
 

iammooks

Active Member
Nov 27, 2018
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is the egr gasket ok? There not dear

This one? It's a bit flat - it could probably do with replacing. I'm guessing it's just a common or garden o ring - do you know what size I'll need?

e39ce090f1834d59096efaddb532208d.jpg




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iammooks

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Nov 27, 2018
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N90927302 is the part number from TPS, VW, SEAT, etc


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Thanks for this - there's a little bit of conflict online as to whether they're 55mm or 61mm, but I'll go with what your part number gives me - the 61mm.


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iammooks

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Nov 27, 2018
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That’s the size for the ARL engine code (FR TDI 150)


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It is, yes. I think the confusion came from an eBay listing I saw where they were selling two different gaskets and one was 55mm. If everything gets delivered on time, I should be able to put everything back together in about a week. Feels like ages.


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Snoopy

Full Member
Apr 24, 2002
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Durham, England.
I know this is an old thread now but i just wanted to say a big thank you for posting all about your experience. I scraped through the mot last year on emmisions on my 130 on plated limit and so was looking for info to try and head it off before this years test later this month.
 
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Rich.T

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Feb 15, 2020
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I know this is an old thread now but i just wanted to say a big thank you for posting all about your experience. I scraped through the mot last year on emmisions on my 130 on plated limit and so was looking for info to try and head it off before this years test later this month.
On the way to the test centre, take the car for a good fast run on the local A road or dual carriageway and get it hot. Give the exhaust a good clear out.

Might give it its best chance of a pass.
 

iammooks

Active Member
Nov 27, 2018
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I know this is an old thread now but i just wanted to say a big thank you for posting all about your experience. I scraped through the mot last year on emmisions on my 130 on plated limit and so was looking for info to try and head it off before this years test later this month.

It's what I started the thread for, so I'm super happy people are finding it useful.

At the moment I'm working my way through things I can do to keep the engine running as smoothly as possible. The EGR valve is clean, and I'm servicing it more regularly now - which is super easy to do yourself when you have time.

In the next few days I'm cleaning the turbo vanes with Mr Muscle and one of these days I'll get round to cleaning the intake manifold.

Otherwise, it's just a matter of giving it some good runs and to avoid using it for short journeys. It's possible to get the emissions to almost half of the plated value even when the car is neglected.


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Maria

my mid-life crisis car
Jun 22, 2016
143
20
South-West
Mine is with the test centre at the moment, always always warm up and clear out any diesel before the MOT!
 
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Maria

my mid-life crisis car
Jun 22, 2016
143
20
South-West
I have a question ... car failed the emissions badly, the only reason I find this odd is that she has been smoking on cold start for 2 years but passed the previous 2 MOTs with flying colours. Anyway - EGR valve and DPF cleaned up and she has her ticket, but still smokes just the same on cold start and now rattles horribly on idle which she never did before.
Any ideas please?
Turbo seems to come in better but otherwise not a huge difference and any positive offset by this very annoying idle rattle..
 

bruceR

Active Member
Apr 11, 2005
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Monifieth, Dundee
I have a question ... car failed the emissions badly, the only reason I find this odd is that she has been smoking on cold start for 2 years but passed the previous 2 MOTs with flying colours. Anyway - EGR valve and DPF cleaned up and she has her ticket, but still smokes just the same on cold start and now rattles horribly on idle which she never did before.
Any ideas please?
Turbo seems to come in better but otherwise not a huge difference and any positive offset by this very annoying idle rattle..

Is yours a mk1?? as these don’t have a DPF!


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Rich.T

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Feb 15, 2020
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How did they clean the exhaust out?
Regen or running a chemical cleaner through the system?
 

Woody_72

Active Member
May 10, 2020
502
251
Northwest England
I recently ran a full can of Liqui Moly diesel injector cleaner through mine and it feels a lot perkier. Remember that the better the injectors can atomise the diesel, the less soot's going to come out the other end.
 
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Maria

my mid-life crisis car
Jun 22, 2016
143
20
South-West
Is yours a mk1?? as these don’t have a DPF!
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Yes Mk1 02 plate TDi SE 110

Work done:
"Strip DPF filter and EGR valve both heavily (gave me a childish giggle with an extra C) COKED up
Soak DPF in Exstream cleaner
Using Exstream spray carry out induction clean through injectors
Refit EGR and DPF
Run and re-test emissions ok"

So Rich T a chemical cleaner through

Fail:
Test type turbo
Test limit applied 0.9
Mean absorption coefficient 1.59

Pass:
Test type fast pass
MAC 0.8
 

Rich.T

Active Member
Feb 15, 2020
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Im just wondering if maybe the cleaning process has damaged the engine oil, ala rattle on idle.
The fluid cleaner may have got into the oil via piston blow bye.
Just a guess tbh but maybe worth an oil change to sort out the problem.
 

iammooks

Active Member
Nov 27, 2018
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Something is amiss there, because none of the Mk1 diesels have a DPF. It's possible that some garages do a standard engine clean that lists a DPF clean as an item, but they'd have a difficult job cleaning something that isn't there.

Keeping the engine breathing well looks to be the most important thing, so fuel system cleaners like the Miller's work well to clear some gunk, along with keeping the EGR and intake manifold clean.

I haven't cleaned my exhaust though - how would that work? I fancy giving it a try - although knowing my luck the soot is the only thing holding it together and stopping the leaks.

I haven't had a chance to clean the turbo vanes, but I imagine that helps the turbo work more effectively and efficiently too.

For the MoT though, an Italian tune has never hurt - but as I've always said, I want the car running efficiently all the time - not just to pass a test.


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Maria

my mid-life crisis car
Jun 22, 2016
143
20
South-West
Im just wondering if maybe the cleaning process has damaged the engine oil, ala rattle on idle.
The fluid cleaner may have got into the oil via piston blow bye.
Just a guess tbh but maybe worth an oil change to sort out the problem.
Interesting thought. The oil was changed when we lost it all on the road back in April thanks to a log and a fail-to-stop, so I was just going to change the filter, but that's an idea maybe.

The rattle sounds for all the world like an exhaust heat shield come loose, or exhaust brackets, and seems to be coming from around the middle part of the car. I struggle to fit underneath these days but can't see anything obviously loose. And it disappears as soon as the revs hit 1000.

I don't suppose it's possible the cat got damaged, is it? It was new 4 years ago. I've tried listening to some collapsed cat rattles on you-tube and it could be but I'm not sure, videos aren't clear enough.
 

Maria

my mid-life crisis car
Jun 22, 2016
143
20
South-West
Something is amiss there, because none of the Mk1 diesels have a DPF. It's possible that some garages do a standard engine clean that lists a DPF clean as an item, but they'd have a difficult job cleaning something that isn't there.

He's an independent old school guy who still uses a paper diary and charges to the nearest tenner and can't give you a price on anything until he's seen the car, not the type to have listed jobs that don't exist. He would rather spend an hour getting your horn or indicators working than throw things away that don't need to be thrown away.

However I'm just wondering if the rattle is quite simply what it sounds like, some exhaust bolt or bracket not back on quite right, which doesn't solve the mystery of the ongoing smoky starts though.
 

Rich.T

Active Member
Feb 15, 2020
1,609
932
He's an independent old school guy who still uses a paper diary and charges to the nearest tenner and can't give you a price on anything until he's seen the car, not the type to have listed jobs that don't exist. He would rather spend an hour getting your horn or indicators working than throw things away that don't need to be thrown away.

However I'm just wondering if the rattle is quite simply what it sounds like, some exhaust bolt or bracket not back on quite right, which doesn't solve the mystery of the ongoing smoky starts though.

Could be an exhaust rattle.
Maybe take it back to him and ask if he could have a quick look underneath.
 
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