Cleaning the intake manifold (ASV) in a Seat Ibiza

Hi everyone,

Despite Dieselmartin's reports, I took the plunge today and started working on my ASV, armed with a pile of parts (all gaskets and screws).

Before that, I changed the oil (which was perfect timing, as it was due for a change anyway, and you can just do it while you're already working on the car). Then, I moved on to removing the intake manifold.

I've documented the whole process with a total of 92 pictures (or had it documented in parts), and I'll be creating a small photo story from them tomorrow or so. Here's just a little preview for now, because I'm quite tired after a full day of crafting and don't want to endlessly comment on more pictures. But here are three already .

Im Ibiza ist die Sache naemlich deutlich enger, als man das nach Dieselmartins Bildern vom G3 vermutet. Der Grund ist recht klar: Das Auto ist fuer 028er Motoren aus dem G3 entwickelt (der alte 6K hatte ja auch AFN, 1Z und AHU), hat aber 038er aus dem G4 (seit dem Facelift 99). Damit ist der LLK links, der Motor von der Ansaugbruecke und dem Turbo her aber so, dass alles nach rechts weggeht. Folglich muessen alle Luftrohre den Bogen um den Motor machen, um wieder von der richtigen Seite zu kommen - konkret heisst das, dass das Ansaugrohr hinter dem Motor quer geht, darunter geht es dann vom Turbo wieder zurueck und kommt vom LLK dann zwischen ESP und Block um die ZR-Verkleidung herum von links wieder in die Bruecke. That's really messed up... you can see it in one of the.Photos below as well.

Damit muss man da einiges zerlegen, ehe man ueberhaupt an die Teile rankann, die man abschrauben willl. Die AGR-Einheit ging recht leicht ab und offenbarte massenhaft Dreck, etwa 2 mm dick am Ausgang zur Saugbruecke (siehe Bild), womit sich die weitere Zerlegung dann in der Tat gelohnt hat. Die Saugbruecke selbst ging nicht ganz so leicht raus, weil man an die Schrauben echt besch.... rankommt, weil die VTG-Dose genau in der Mitte davor ist. With a bent Allen wrench and a long-handled lever, it finally worked – actually, the screws came out easily, and basically every part looked brand new.

The bridge itself, on the AGR side (the ASV bridge looks different from the one in Martin's video; the AGR system feeds debris *before* the bridge, not into it - we'll see that in the pictures tomorrow), also had the aforementioned 2 mm of dirt (see picture). Towards the cylinders, there was a layer of slime about 0.5 to 0.8 mm thick. So, it's nowhere near as dramatic as Martin's, but it still took a long time to verschandeln with gasoline and brake cleaner, although I didn't do it quite as meticulously as he did.

The assembly process was actually quite uneventful, and after that, the car started working again...

That's all for now... I'll add more details to the descriptions tomorrow.

Best regards,

Jan.

Hi,

As promised, here's the link to the photo story:

http://www.uyna.de/auto/agr/index.html

I've recently taken or had taken some more photos of various VTG parts, and if anyone wants to use these images for articles, please feel free to do so. If needed, I can also send the original images, but they were taken with a 4-megapixel camera and are quite large in size.

Best regards,

Jan.

Has this whole action achieved anything? In terms of performance or consumption?

Hi,

It's difficult to say definitively because I also replaced the oil, oil filter, and air filter at the same time, which can all affect these parameters. Furthermore, the cross-section wasn't significantly narrowed, so the differences are likely below the level of measurability.

After the MFA (presumably a maintenance or service), it consumes slightly less fuel and he feels more agile, but that's probably due to the combination of all the measures taken. It's quite clear that a new air filter puts less strain on the turbocharger compared to one that has already covered 47,000 km and was only cleaned every 15,000 km.

What it definitely does: It gives you the good feeling of having removed a lot of gunk from the engine. You certainly can't measure that in horsepower or milliseconds during acceleration.

Best regards,

Jan.

Jan6K wrote:

What it definitely does: It gives you the good feeling of having removed a lot of gunk from the engine. You certainly can't measure that in horsepower or milliseconds when accelerating.

And now what?

Do you want to keep having the same problems every ~40,000 km, or would you rather prevent them?

Hi,

Working one day every three years... it's not actually that bad, is it?

Best regards,

Jan.