Intake manifold clean on an Audi A5 3.0L

A few weeks ago we had an Audi A5 3.0L 2009 Turbo diesel come into the shop with an engine light on the dash and running issues. After looking into the engine light, we found various codes relating to insufficient flow in the EGR system and excessive soot accumilation inside the Diesel Particulate Filter. After removing intake manifolds for a closer look, we found a large amount of carbon build up plastered to the inside of the manifolds, swirl flaps and EGR valves.

The Audi had just over 140,000kms on the clock and combining that with a majority of around town driving, minimal highway kilometres and poor service history it came as no surprise seeing how much carbon build up this engine had.

This video shows the process of how we pulled apart the cold side of the engine including intake manifolds, EGR valves, throttle bodies etc and manually cleaned them ourselves on the bench. Once clean enough all parts entered the next stage of cleaning by sitting in our sonic bath for several hours. Upon completion, the fun part began with all clean parts being reassembled and ready for the final stage of cleaning.

Once back together and with the engine running, a full induction system clean and fuel system clean was done using our BG specialist equipment and materials. Later on a full oil and filter change was done using BG Engine Performance Restoration additives, and both air and fuel filters were replaced topping off with an Air Mass Sensor clean.

After completing the above work, we still faced one issue. We were not able to complete a forced regeneration of the Diesel Particulate Filter using our VAG COM scan tool and the engine light was flashing. Luckily we were able to test the DPF sensor using our Picoscope which showed that Sensor 1 was unresponsive at idle and at increased RPM. This gave us the understanding that DPF Bank 1 Sensor was faulty. The faulty sensor was replaced which showed an imediate improvement through the Picoscope. This then allowed us to complete the forced regeneration of the Diesel Particulate Filter, clear the final code for the engine warning light, and complete the service of the vehicle.

Its safe to say this car left the shop running a whole lot better as to when it first came in!!

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[lukeolyslagers]

Nice and clear video! Do you have a de-carbon product you recommend for these engines?
Coming from the Subaru world, I'm used to using their Upper Engine Cleaner to keep things clean but I'm unsure what to use on my Audi now I've scraped the mountains of crud from the intake post EGR.

[quintonlehy]

How does one prevent this carbon build up in the intake? My Touareg 3.0tdi might have the same issue, and I’m a bit scared to open her up.

[kiwi]

great video good honest workmanship this is just what my A5 needs i been getting the PO 401 code coming up so de-carbon would be good i hope

[bradbridgewater]

Hello buddy what was the last sensor you changed