Hello everyone!
Since my friend recently bought a Polo 1.9 SDI, the weekend seemed like a good opportunity to take a closer look at it.
1. The problem of returns always comes up; I thought that wouldn't be a problem, it's just a frame and a gear system!
I thought!
After 2 hours of adjustment (at the long hole and on the rod!), things hadn't improved at all. So, I simply detached the rod and manually engaged the reverse gear, securing the whole thing with a thick cable tie.
After a few meters, the cable tie simply broke, and it popped out
. It also pops out when you hold the shift lever in place!
Is the gearbox messed up? Can I disassemble it using standard tools? Can I adjust anything on the shift forks? - All other gears shift normally.
2. Problem: It was misfiring at full throttle, not severely, but it was misfiring! The error memory was empty.
First, I replaced the air filter, which actually didn't look too bad. Then, I removed this plastic cover from the intake manifold
. What I saw underneath is indescribable; it was so covered in soot and oil residue, it's truly unbelievable (photos will follow, I only had an old-style camera). I immediately removed these strange plastic intake pipes, including the intake manifold, and saw that the 4th cylinder was completely blocked up to half its height (no exaggeration, you'll see the photos!).
I first soaked it in gasoline and then scraped it off, which was a real mess and it didn't come off easily!
I carefully removed the soot and ash from inside the head and vacuumed it out (of course, I made sure to keep each valve closed!).
"As a little extra, I added a Hohnstein to the intake manifold, then reassembled everything. (It's pointless to leave the plastic tubes exposed because the intake path would be too short, and it would lose almost all its power!)"
I used a piece of metal, cut to the size of the gasket, to seal the AGR valve, and surprisingly, it doesn't produce any soot anymore!
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