Go back to PT1: Parked for years! Resurrecting a VW Golf TDI Diesel 1.9! https://youtu.be/nYcm86IZR34
Check out my Merchandise (because I don't say MERCH) Store Below the video for Men's and Women's Apparel, MUGS and Stickers!
Send support on Patreon, check out the bio: https://www.patreon.com/RainmanRaysRepairs
Patreon is a "Tip Jar" I don't post much there, daily YT uploads are all that I can manage right now
Must have for any toolbox!
New Addition: Same as Matco. Mountain 5-Piece Metric Double Box Universal Spline Reversible Ratcheting Wrench Set; 8 mm - 18mm, 90 Tooth Design, Long, Flexible, Reversible; MTNRM6 https://amzn.to/3OJTRp2
Mercedes BMW VW Wheel Stud Master Kit: https://amzn.to/3OszRaL
Bahco "Frustrated" Pliers AWESOME tool! https://amzn.to/3IfDeOa
Brake Caliper Compressor: https://amzn.to/3gQBuiB
GearWrench Hose Clamp Pliers: Currently Unavailable
My Camera Gear:
Gopro Hero 8 https://amzn.to/3mPnpFA
Gopro Hero 9 https://amzn.to/3EKDcM1
Hero 8 Dual Charger https://amzn.to/3EId84c
Flexible Camera Mount https://amzn.to/3Jywrk5
As an Amazon Associate I earn from qualifying purchases. #commissionsearned.
Also, I personally use or have used the products featured in my links and only recommended them if I feel they are of good quality.
“All the videos, songs, images, and graphics used in the video belong to their respective owners and I or this channel does not claim any right over them.
Copyright Disclaimer under section 107 of the Copyright Act of 1976, allowance is made for “fair use” for purposes such as criticism, comment, news reporting, teaching, scholarship, education and research. Fair use is a use permitted by copyright statute that might otherwise be infringing.”

Try again all right folks. It's the next day. And we're still on on this volkswagen golf last video. We did an inspection on this car.

Four tires put on we found a couple oil leaks found a bad battery and the fuel filter needed to be replaced. We left off at the beginning stages of the valve cover removal. I had to pull the egr valve off of the intake manifold and found loads and loads of carbon caked on on the inside of the valve. We're going to go ahead and finish.

Removing all the carbon deposits that we found and then get this valve cover removed. So stay tuned. This is going to be a really good video oh look at all that that i'm surprised this thing even worked at all that's wild hey i've got to clean that out that's terrible here let's go to work on this valve next here i'd like to make this easier to clean up there oh that is so bad okay so this is the valve right here yeah. This is the valve.

It's actuated. It opens and goes that way opens up and that allows i think egr passing get this out of here nasty. That's probably good better than it was i know that foreign shiny beautiful even better after you wipe it look at that all right let's just set our newly cleaned valve over there and that can uh if you stay there until we need you what we're interested in is these scratches inside of this intake are from me trying to scrape away the carbon all right loud noises let's clean this out we covered that part in the last video. But it looked really bad and i wanted to offer explanations and we need you what we're interested.

In is there they are those two bolts right down. There you see them there's one there's the other one all right let's see if i can get a wobbly on them. I think i can foreign loose. I can't seem to get that bolt out so i want to see if they remain in the cover or not sometimes they do yes.

This is one of those times. Okay thank you so far so good. I'm curious about this timing cover. I wonder.

If i have to remove this first before the valve cover comes becomes great. I guess we'll see foreign reverse click. That was nice. I think there's one more me too all right let's pull these fuel rails back some those are out of the way dude pry bar.

Again let's try pry driver. Okay i see this cover over here does come off. But it's uh very simple clip on operation good can't reach. Though we gotta pull this intake tube off and way down.

There is the other clip for this cover. I can't see it. But i can feel it very nice all right all right tell me here okay all right all right here. Wow.

It appears i have underestimated volkswagen they have rather large and dirty injection units. I mean i'm impressed look at that what we have here is an injection unit that is electronically operated. Yet the high pressure is supplied via the camshaft and this rocker arm as the camshaft rotates. It depresses.

This side of this rocker pushing down this plunger and that's what creates the pressure in the doo doo doo doo chamber that's what creates the pressure for the injector to spray and atomize. The diesel it appears that this pump is just a low pressure uh volume pump. It's just designed to move the fuel and the fuel runs into the head ends up at the injectors. The cam runs cam pushes down pressurizes the fuel solenoid opens up sprays the fuel into the cylinder boom explosion.
We have made power and the intake and the exhaust valves are run over here off the cam. Actually the camshaft is here it appears that these are just rocker shafts for the injectors so down there that littler guy. That's actually the cam back in there because we see here we've got an intake or an exhaust. An intake and an exhaust talking about these lobes right here another one there and another one there.

I like it all right let's go ahead and wipe off all this oil that way when we put the new cover for the cover with the new seal back on nice and clean oh and we do need to add a little bit of silicone on these end caps right here. I don't see any that might be the reason that it's leaking so heavily over here on this corner. There's no sealant between the two metal parts. There nice and shiny yeah.

There's a little gap right in here. Very very very tiny gap zoom in a little bit. And if you don't have any liquid sealant in that little gap. It'll wick out and leak.

Okay let's just sneak our bottle of sealant in there not gonna work i have to do this with the finger. Thank you i thought i could just get the bottle in there. But i thought wrong and there we go just kind of smear that in there. It's kind of ugly looking.

And i know it didn't already come with it. But that could have been the source of the leak and it won't hurt that i'm putting it on there okay two more dabs on this other side over here. Thank you and uh one more in the back. Oh.

I'm in the way of the light. Okay dabs of sealants are in position let's go get the valve covered. I've already gone and changed out the gasket. It's fairly uneventful okay same way it came out nice and easy foreign.

Oh nice. This is good beautiful all right let's start torquing this down start for the inside and work our way around click all right. I think that's the last one i'll double check them with the torque wrench later now for my next trick. We'll put the cover back see.

It's got one clip right here one more clip right here. And it just slides down and clips on what will it be for me to line. It up there's a lot of stuff in the way. What are you stuck on stupid uh.

Oh something bad happened what are we stuck on down. There this is dumb nothing. I don't i'm going to defeat. The obstructions here there we go target somewhere i got it in as far as i've gotten it in so far.

So that's progress pull it out some try again different angle. Maybe close. I can see that it snows. Very non compliant component.
There we go just needed to jiggle it some flip flick and another two boost pipe that's connected that's back on taking these back all right let's put our idle air control unit back in egr unit. I don't know why i keep calling it an iac. It's because it's a really small engine and uh. The fact that it's a diesel is not uh settled in with me yet.

This is sealed with an o ring by the way. Which is also in good condition therefore. I'm not replacing it additionally. I didn't know i was taking this off so i never ordered it but that'll be just fine three whatever song pete is playing i hear chewbacca in the background of it oh well somebody has chewbacca.

I think it's you click uh where's my connecting connector shiny all right this little hose go back in that's a pcb hode. All right we're pretty good with the exception of uh of that turbo pipe. I'm waiting on that all right real quick. We're back underneath this and i'm just gonna get this turbo drain back in so.

We can uh come up with a little bit of closure on this job here. I'm uh. I'm trying to get the gasket off the bottom of the turbo and it's it's not being very compliant with my will pretty stuck on the turbo. There it is got her huh look at that i moved through the matrix got it all right.

I've got the new drain back pipe right here got the gasket and i've got one of the bolts going through the flange. We're gonna get one of them started and then i can reach up there and get the second bolt in kind of a balancing ax going on right here. And it's far away and i cannot reach i uh i got the nut or the bolt in between two fingertips. I'm trying to get some rotation out of it it's uh difficult to achieve i get it persistence feel bad you guys can't see what oh gravity's getting after me all right i need to rethink this all right.

We're going to try the same maneuver again. Except. I'll use the torx feature of this bolt instead of uh trying to stick my fingers up there turns on it there oh i'm dumb. I got it backwards that hang on trying again all right well that's fine.

I won't be here. No. I don't have to all right next bolt s. What up man.

What do you need you need to get that lower arm up again okay hang on let me let me get this thing okay. I'm back i had to go do some teamwork activities come on you get in there there we go now we're cooking not that easy come on here. I think what i'm going to do is engage in some long range pry bar action. See this thing is not sitting straight.

And so it won't thread. I need to kind of move it over. But i really can't so i'm just gonna mini pry bars with a long screwdriver just to get pressure off of it and then i should be able to thread this fastener maybe yeah. It needs to go way over that way okay.

This is more difficult than it should be or i just am not good at volkswagens. I got her yeah we're good we're good we're good we're good wonderful sorry if my uh my flanges are blocking yellow's view. That's on now let's make it a little tight wrong wrench. It's fastener got me twice got me once when i was taking it off and got me again just now 22 millimeter.
A little bit more for good measure. Because i feel like it not yet good and tight and clickage the compression fitting is compressed let's get out of here and put oil in this thing. We are nearly finished all right volkswagen coming down. Oh hey.

So i've got a confession to make i kind of lied to you guys um. I said earlier when we first started working in this car that i was going to save this window for later. And i started to do a video on it and um well let me back up first. I have finished the the window.

It is now repaired. I've put a new regulator in it i started to do a video on it. And it was going horribly bad. This is a very very meticulous and pain in the butt job to complete the filming of it was horrible.

The lighting was ugly um. So i the video didn't go so well so i abandoned it about halfway through so for those of you who wanted to see that i apologize. I've let you down um. I'll try to do better in the future.

But this one just wasn't working out it happens. There now that awkward moment's out of the way let's finish up here let us stopping z. Engine check it for oil leaks running out of fuel. It has to prime man and we're out of fuel try again restarting the engine widow throttle that took longer than what you saw because i had to edit that out it was boring.

That was about 20 seconds of cranking with throttle fully held it primed up the filter. Because when we put that new filter on that was full of air. So it was able to draw enough fuel in with a little pump to prime that filter. And once fuel reached the injectors again back to life oh yeah proof of window.

What a cute little turbo diesel. See if we can hear the little turbine can't hear it baby turbo. Say this thing really has some torque. What was that something make a crunchy noise.

Did i run something over what was that that didn't sound cool emergency stop. I either ran something over parts fell off. And i know i have all my parts and tools let's go check that tell you what there's nothing like here in sudden crunching noises. After working on a card take care of the life out of you and i know nothing fell off all right not not here.

Heck was that i'm gonna have to go back and see what's laying in the road maybe. I ran something over did you guys see anything i didn't see anything all right i don't hear the crunchy noise. I actually have three arms until i'm able to do this no i'm just kidding. I i drove a stick shift in high school.

I can shift and do things with my hands at the same time skill okay yeah i want to go back and see what we ran over that was concerning to me it scared me a lot. It's fair. I need to merge using indicators. Contrary to popular belief.
The turn signal is not a speed up and get in that person's side indicator. It's not that far. However when i turned it on that guy over there he went around a bunch of people didn't cut us off only to come up to a red light that guy now the real test is gonna be can i shift and do a u turn at the same time without wrecking into that pole right there because that would hurt and we're off don't honk at me guy behind me. There's a shift haha.

I did it we're in second gear. See you aren't looking around whoa brakes. What are we doing downshifting. I'm gonna go over here.

Oh nice turn signal nice good job good job red rules cadillac hope you watch my channel. I'm getting pulled over by a robot. Okay let's see we pull it over like right here. That means.

The clicky noise. Happened right over here. I don't see anything in the road. Let's turn around and go back let's uh.

Get a closer look out of this situation here. Oh that car got in my way objects in the phone are closer than they appear see we'll do some knee steering shifting there we go knee steering shifting clear the curb nice. I don't think i'm gonna see what i well whatever might be there i wonder what it was oh well. It wasn't the car that's all that matters as always like thank you for watching this video hope you enjoyed this video.

If you did enjoy this video. You know what to do let me know about that by tap. It tapping that like button down below so again as always thank you for watching. And most importantly don't forget to have yourselves a great day see you guys later.

93 thoughts on “Valve cover turned clogged egr! vw golf 1.9 diesel!”
  1. Avataaar/Circle Created with python_avatars Greg Diamond says:

    Bless you Ray, for fixing a car that should be parted out.🙂

  2. Avataaar/Circle Created with python_avatars Glen Fynney says:

    nice to see you changing gear with the correct hand…lol (from a brit….lol)

  3. Avataaar/Circle Created with python_avatars Rick Sawyer says:

    Guess I need to check and clean that on my TDI with 318k on the odometer

  4. Avataaar/Circle Created with python_avatars Philip Ershler says:

    If a window regulator gets changed and there’s no one around to watch it, did the regulator “really” get changed?

  5. Avataaar/Circle Created with python_avatars d burly says:

    Stop having so much fun Ray!

  6. Avataaar/Circle Created with python_avatars David S says:

    No parts washer.?

  7. Avataaar/Circle Created with python_avatars Scooter30FTW says:

    I never knew there was a doot toot doo doo chamber.😆

  8. Avataaar/Circle Created with python_avatars Zachary Reilly says:

    Can you please post non-HDR videos(maybe along side the normal ones) it keeps changing my brightness and makes me not want to watch your videos

  9. Avataaar/Circle Created with python_avatars Anthony Wheeler says:

    That’s not as COKED up as Hunter Biden. All jokes aside, I’m heading to bed now. Thanks for the entertainment and info you share.

  10. Avataaar/Circle Created with python_avatars TankGuy3 says:

    Ugh, how much would it cost to change the do-de-do-de-do chamber?

  11. Avataaar/Circle Created with python_avatars BILL KILLMAN says:

    I am jealous every time I watch you work on a older car… I'm in the rust belt of Michigan. When I see a exhaust or a suspension bolt I cringe thinking what my % of having to drill it out…

  12. Avataaar/Circle Created with python_avatars wheels993 says:

    If there’s a will there’s a way.

  13. Avataaar/Circle Created with python_avatars Toby Tesh says:

    Did anyone else see a stall out in his u turn

  14. Avataaar/Circle Created with python_avatars Santa Mike says:

    You need to shave those harry arms if you are going to do close ups like that. LOL🤣

  15. Avataaar/Circle Created with python_avatars jh yh says:

    the noise was probably the bumper noise the guy was talking about

  16. Avataaar/Circle Created with python_avatars Julius Roberts says:

    That was a cute rabbit that went CRUUNNCCHH!!!

  17. Avataaar/Circle Created with python_avatars G Crauwels says:

    Quite a bit of carbon in there, but I had heard those TDIs do that. Interesting setup.

  18. Avataaar/Circle Created with python_avatars julius liles says:

    I would advise you to never smoke around das auto's, the crunchy sound would have been followed by flames.🔥

  19. Avataaar/Circle Created with python_avatars Bigsquatch Sasfoot says:

    That valve was dirtier than my ex girlfriend 🤪

  20. Avataaar/Circle Created with python_avatars John Regal says:

    Best thing to do to unclog the plumbing on those cars is take the Intake Manifold off and soak it in a bucket of diesel for 24 hours, then clean it out. My old TDI mechanic in Maine always had 2 or 3 used intakes laying around for his customers. Take the old one off and soak it, put one of the clean used ones on. I loved my 2003 Jetta TDI 5-speed. had 367,000 miles on it when i sold it for $500.

  21. Avataaar/Circle Created with python_avatars Garry Tustian says:

    Ray, how often do u have to clean out the EGR Valve? I have a 2013 Hyundai Santa-Fe Highlander 2.2 Diesel. It has been cleaned out once by the Dealers Workshop & the SUV has ONLY 29k on the Clock. Thanks from Down Under.

  22. Avataaar/Circle Created with python_avatars Brian Johnson says:

    Hey ik you killed the car when Turing around 😂 got ya love ya ray

  23. Avataaar/Circle Created with python_avatars JT says:

    That noise must have been a cat that kept running.

  24. Avataaar/Circle Created with python_avatars Jeff Smith says:

    I really like this little thing. Cool little car.

  25. Avataaar/Circle Created with python_avatars Aaron Burson says:

    Maybe you ran over the Easter bunny. 🙃

  26. Avataaar/Circle Created with python_avatars Shane Schneider says:

    Great Vid! Been bingeing for about a week, just Subbed.
    I miss the shops so much. Broke lower back in '05 and had to walk away.
    Sounds like someone got a newer radio, the bass is more bassier (on my headphones) …

    Keep on keeping on! Make everything shiny and beautimus!

  27. Avataaar/Circle Created with python_avatars Peasant Garage says:

    The parts falling off this car are of the finest German quality!..lol

  28. Avataaar/Circle Created with python_avatars I am Linda says:

    I have a question? Why do your videos hijack my brightness settings? Am I the only person this happens to?

    I love your videos, I just don't like getting blinded by the brightness.

  29. Avataaar/Circle Created with python_avatars Anthony W. says:

    Reeeeeee! You're touching their steering wheel with your dirty hands! Reee!

  30. Avataaar/Circle Created with python_avatars Tristanwendt says:

    I think he needs his intake manifold cleaned too lol

  31. Avataaar/Circle Created with python_avatars Steven Trostle says:

    Neat Engine, Thanks. Looks like what I'd call a 3 band aid job.

  32. Avataaar/Circle Created with python_avatars Daniel Scott says:

    Pile of gravel you ran over before you pulled out onto the road probably had something to do with the crunch sound. New tires are notorious for picking up rocks.

  33. Avataaar/Circle Created with python_avatars David Lagle says:

    That's a great car.50 MPG

  34. Avataaar/Circle Created with python_avatars Don B says:

    bump was inner fender???

  35. Avataaar/Circle Created with python_avatars Turbo's Inc says:

    Vehicle should return rather quick with same issue as issue has been resolved but not the cause of the issue.. just advise.

  36. Avataaar/Circle Created with python_avatars Turbo's Inc says:

    The turbo has started seeping oil past seals seen in intake pipe (Boost Pipe) also part of the reason why crabon buildup is so aggressive mixing oil …easy fix should start repairing turbos in your shop too rather than replacing.

  37. Avataaar/Circle Created with python_avatars bonza167 says:

    would a catch can fitted after the PCV to catch oily mist entering the intake reduced some of the carbon build up from the EGR? I've heard conflicting reports of this. some say it does, others say that if the soot is dry without oily fumes it becomes abrasive and causes intake valve wear.

  38. Avataaar/Circle Created with python_avatars Michael Faraday says:

    Wow, they had some engine stuck in their carbon.

  39. Avataaar/Circle Created with python_avatars S Young says:

    What kind of oil did you finally used? I think that one takes a special oil because of the pump duse tdi.

  40. Avataaar/Circle Created with python_avatars Sam Spock says:

    Making me miss my 2005 Passat TDI. Had a slightly larger version of the same engine.

  41. Avataaar/Circle Created with python_avatars xAnortonx says:

    Honestly I would’ve recommended the egr delete kit. I’m sure someone’s already said it but screw it, it’s Florida nobody cares about emissions

  42. Avataaar/Circle Created with python_avatars Alesky Finis says:


  43. Avataaar/Circle Created with python_avatars badassbiker1974 says:

    Finally a vehicle I recognise from the UK. Nice work Ray. 👏 👍

  44. Avataaar/Circle Created with python_avatars joe lees says:

    V dub window regulators suck ass to replace

  45. Avataaar/Circle Created with python_avatars neildowntotheking says:

    I have never seen a Diesel engine timed with a belt, all of the engines I’ve worked on at a CAT dealership and at a forklift dealership have been timed with gears. Very interesting, there must be some kind of negotiating room for vehicle engines versus industrial engines, perhaps a VW tech can enlighten me and the crowd. Regardless, excellent content Ray!!!

  46. Avataaar/Circle Created with python_avatars Brian Phillips says:

    I would personally delete that system so no more clog. Unless you live in a state that test emissions

  47. Avataaar/Circle Created with python_avatars stanley koziol says:

    It may have been the broken inner fender hitting the tire

  48. Avataaar/Circle Created with python_avatars DKzAcronym says:

    LOL "in the doo do do doo chamber"

  49. Avataaar/Circle Created with python_avatars Steve M says:

    It should have a lift pump. Next time cycle the key on for 30 seconds, then off about 5 times and it will prime the fuel filter. Also I was curious about the oil used in the oil change which you didn't show. Hopefully you didn't just put dino oil in. VW is specific about the VW spec synthetic oil to use in their diesels. Failure to do so will result in rapid wear of the cam lobes, bearings, etc.

  50. Avataaar/Circle Created with python_avatars Mizzy4106 says:

    2005 GMC 2500hd 6.0l nv4500/zf6 best truck ever buily

  51. Avataaar/Circle Created with python_avatars James Kennedy says:


  52. Avataaar/Circle Created with python_avatars Mizzy4106 says:

    I wish trucks were still MT

  53. Avataaar/Circle Created with python_avatars Black III says:

    That VW needs oring lube on that EGR valve