[Vwdiesel] 04 TDI Golf intake issues on trip

[Travis .]

I should have mentioned but I was too tired to remember everything-a 6 month old still breast feeding and a potty trained 2 yr old that add 25% more time to the trip. 

I have the EGR cooler and pipes deleted and I have the lower flappers taken out of the intake but do still have the anti-shutter (the big individual one at the top of the intake manifold) still in. I also have a "dog collar" holding the intake pipe in on the top as it was loose once. I am thinking the Aluminum EGR exhaust manifold cover may have melted some on the Mts. I was pushing hard to clean things up and that is the first time since deleting the actual EGR cooler/lower pipe. I will update later to see what I find.
Travis

Date: Mon, 20 Aug 2012 07:27:47 -0500
From: dieseltdi at verizon.net
To: tgott at hotmail.com
Subject: Re: [Vwdiesel] 04 TDI Golf intake issues on trip

Travis, make sure you check the EGR exhaust pipes.  These will develop exhaust leaks that can squeal like you describe.  You may also have a partially loosened boost hose. Especially check the connection of the main hose to the flapper assembly.  Hope is isn't anything serious.  Hayden   On 08/20/12, Travis .<tgott at hotmail.com> wrote: 
Traveled around 1500 miles now from WI to WY. Did 500 today from Sheridan WY to Billings MT to visit someone and then do the Beartooth Mts and Big Horn Mts on the way back. When I got to the top of the Big Horns I started to hear some squealing like are trying to escape a bottle. After doing that to all the bottles I still hear something. Didn't take long to see/hear it was the car. Couldn't find the source in the dark. Didn't seem to affect things enough to strand me so I drove-slowly the around 50 more miles keeping the boost at/under 5 PSI as that is where the sound started to get really bad. Seems to have full boost. Doesn't make any noise at 2-3 psi. 

I can't believe the turbo is really failed if it still boosts and didn't suck the oil in. That is about all that can go wrong. I would think if it was making metal it would have done something by now with either the engine really going/sounding bad or something. Sounds fine other then boosting it. 

I am hoping for the shut off flapper in the intake manifold to be the issue. Maybe it is stuck part closed. I will have to start pulling things and see. I am a long ways from home but thankfully am staying with some friends who have tools and I have the week off. It just depends on how I will be spending it and how my family and the car get home. Hoping I don't have to rent a U-haul or something but we shall see. Any tips let me know.

Travis G

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