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Exhaust manifold leak, BKD engine

 
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Stierkaempfer



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Post20-12-2015, 11:20    Subject: Exhaust manifold leak, BKD engine Quote

Good morning.

Due to acceleration and idling issues, I have an appointment at the workshop to have the throttle body checked/replaced. During yesterday's inspection, I discovered a leak in the intake manifold.
I will have the clutch replaced as soon as possible and hope that this resolves the jerking problem.
In the log, cylinder 2 shows occasional misfires, and at idle, it has a fuel quantity reading of 2.99 mg/hour.
The intake manifold is covered in soot on the right side, near the two middle cylinders.
Is that the intake valve for cylinder number 2?

Thank you.
2.0 PD TDI 140PS BKD


Translated on 21-07-2026, 0:42.
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2002 Volkswagen Golf Consumption
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Post20-12-2015, 13:57    Subject: Exhaust manifold leak, BKD engine Quote

No, that's cylinder number 3.

Edit: aside from that, you mean the one on the right side when looking at the engine from the front, and not the right side on the passenger's side. icon_wink.gif
MfG. Michael

VW Golf IV TDI GTI 4-Motion Bj.2002 MKB/GKB: ARL/FEK
VW T4 Pritsche TDI Bj.1999 MKB/GKB: AXG/AFK (Selfmade)


Translated on 21-07-2026, 0:43.
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Stierkaempfer



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Post20-12-2015, 14:39    Subject: Exhaust manifold leak, BKD engine Quote

The engine is mounted transversely (or sideways).
Looking at the engine, I see the timing belt on the left side. Counting from left to right, it's the third cylinder.
2.0 PD TDI 140PS BKD


Translated on 21-07-2026, 0:44.
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Post20-12-2015, 16:30    Subject: Exhaust manifold leak, BKD engine Quote

Yes, then it is indeed the 3rd cylinder, because the counting starts from the side that delivers power.*

* Also, a quick note for the future: Not every manufacturer (like French ones, for example) handles it this way! icon_wink.gif
MfG. Michael

VW Golf IV TDI GTI 4-Motion Bj.2002 MKB/GKB: ARL/FEK
VW T4 Pritsche TDI Bj.1999 MKB/GKB: AXG/AFK (Selfmade)


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Stierkaempfer



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Post20-12-2015, 18:39    Subject: Exhaust manifold leak, BKD engine Quote

Unfortunately, cylinder number 2 is clearly the problem.
Let's see what happens after the seal replacement.
2.0 PD TDI 140PS BKD


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Post21-12-2015, 8:59    Subject: Exhaust manifold leak, BKD engine Quote

Quote:
Just a heads-up for the future: Not every manufacturer (like French ones, for example!) handles things this way! icon_wink.gif


There are also German companies that don't operate in that way, for example, Deutz.

Quote:
Unfortunately, cylinder number 2 is clearly the problem.
Let's see what appears after the seal replacement.


Take a look inside the intake manifold once the blower is removed. You might be able to see the condition of the valves (and how dirty they are).
A value of +2.99mg is more likely to be attributed to issues with the pre-combustion chamber (PDC). Engines with an added intake manifold typically run smoothly in low load and low RPM ranges, as there is relatively ample time for filling the cylinders through the constricted cross-section.
selber schrauben - statt Werkstattpfusch


Translated on 21-07-2026, 0:46.
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