D3 4.0tdi any issues ??

[roberto]

thinking of buying one as a cheap run-around
any issues with this old engine and gearbox?
thanks

[ainarssems]

The biggest issue with 4.0TDI is intake manifolds braking down with age and sending bits into engine which kills engine. In most cases engines are not repairable and not economical to replace which means cars are written off. Intake manifolds cost over £1k each so not economical to replace as preventative measure either. In my opinion warranty is a must if you go for 4.0TDI unless you can find one which had manifolds replaced recently.

[roboblob]

I am wondering if anyone has ever tried taking off the manifold and adding a fine light heat resistant mesh over the gasket and refitting as a safety net as such just in case bits fall off.

[roberto]

oh dear
is this why there cheap now £5,000 ish for a £55,000 car new
well breaking for spares would make a bit of money back i suppose if it went wrong
put me off a bit that i must admit

the heat-resistant mesh sounds like a plan but how hard is it to do i wonder

[webs289]

We use zylon mesh on the F1 cars airbox to stop rubbish getting in, bonded with high temp glue. My have a go with that option soon to prove the theory. I also thought of making some mods to an already damaged unit with composites if i can get one :-)

[ainarssems]

Depends how close to head swirl flaps are, if they are protruding from manifold when open mesh will get in the way. What about vibration, it might be OK for short distances in F1 but will it survive 50k miles? If some bits get loose and rattle around they will surely wear through sooner or later. It will also reduce airflow and power, increase back pressure and make turbo work harder, less efficient, increase charge temp. Many diesels are known to clog intake manifolds with carbon build-up from EGR+engine breather system so it could clog up mesh at least on the swirl flap side as airflow is lower on that side most of the time.