Did my EGR delete!

[GoLfMan]

Got my EGR delete pipe today thanks to Darkside Developements.

however I ordered the wrong size because I didn't take the EGR assembly off to measure. Apparently the aussie Polo TDI's have PD150 intakes stock :facepalm: its ok though, its the same size as the stock intercooler piping, so for now it will do, until I finish my FMIC install over xmas :cookie:

easy to install, nice welds, and nice mill job on the flange :)

I'll post some photos of what my stock EGR looks like. Its really not that bad! (I had my intake cleaned at 90k, then soon after I played around with VAG COM and shut off the EGR as much as I could. It obviously works!)

plenty of work to come on Sooty.
things to come:
- FMIC install
- custom dump pipe + high flow cat (ceramic coated)
- fix a few niggles


the plan is to get everything I need in order to just bolt on the VNT17 and new injectors + a tune, so when the little snail gives out it won't cost me the world :)

[Buller_Scott]

yeah man! so it was a pretty easy job? i'd be interested to see if it'd be possible for me to do the same (egr delete, at least), and truth be told even if i couldnt tweak anything in vag com, i really wouldnt care about a CEL staring me in the face.

show us some pics!!!!

[GoLfMan]

yeah man! so it was a pretty easy job? i'd be interested to see if it'd be possible for me to do the same (egr delete, at least), and truth be told even if i couldnt tweak anything in vag com, i really wouldnt care about a CEL staring me in the face.

show us some pics!!!!

piss easy, just slightly fiddly. Will post pics soon.

Might even sell you my EGR delete when I get my bigger one if you want?

[Buller_Scott]

when you get a bigger EGR delete for bigger diameter FMIC piping? hm..... that might not be a bad idea.

[GoLfMan]

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/2a9654a21-2.jpg

**NOTE: the blue silicon is temporary until I do my new piping

[GoLfMan]

when you get a bigger EGR delete for bigger diameter FMIC piping? hm..... that might not be a bad idea.
that's it fella! I'll be going 2.25" piping all around :)

[gldgti]

What did you do with the plugs?

I'd be pretty interested to know what you did with vcds to turn down your egr.... i got my cable tis week, only plugges it in once and had a quick look around after work but havn't had much of a chance to look at it yet.

I saw egr related stuff and even "charge pressure control" - so I can up the boost myself I guess?


I wonder what else is required to just do my own tune...? haha

[GoLfMan]

What did you do with the plugs?

I'd be pretty interested to know what you did with vcds to turn down your egr.... i got my cable tis week, only plugges it in once and had a quick look around after work but havn't had much of a chance to look at it yet.

I saw egr related stuff and even "charge pressure control" - so I can up the boost myself I guess?


I wonder what else is required to just do my own tune...? haha

What plugs? The vac line and the electrical plug? I just plugged the vac line andcable tied them out of the way.

in regards to turning down your EGR. There is an article on TDI club somewhere, you change a value and it basically shuts it off. Search it :)

Doing your own tune would be fairly difficult I would assume! But if you find a way let me know :D

also had a chat to the fellas at Darkside. The 51mm is the recommended for stock IC piping, because its the same size. Will upgrade to the 57mm when I do my FMIC.

[jfoldbar]

ive often thought about doing this with my t5, but too nervous. heard stories like it can increase temp and decrease life. does it make any difference to your polo?

[GoLfMan]

ive often thought about doing this with my t5, but too nervous. heard stories like it can increase temp and decrease life. does it make any difference to your polo?
well in the case of my Polo it blows less smoke under hard acceleration, less smoke as I understand it means lower EGT's.

I really dont think it would raise the EGT's enough to kill the turbo that much faster! But I haven't logged it vs. stock so I don't actually know!

All I can say is try it, its not expensive and its easily reversible :)

[jfoldbar]

mine doesnt blow any smoke in order to make less so its not that im after. my main desire is reliabilty. if i delete something then i think if its not there it cant break?

[Greg Roles]

If you are at all concerned, put in an EGT gauge first. I have to say I've noticed no heat difference on my EGT's with no EGR, but then my car is getting a lot better cold airflow than stock these days.

[Preen59]

If you are at all concerned, put in an EGT gauge first. I have to say I've noticed no heat difference on my EGT's with no EGR, but then my car is getting a lot better cold airflow than stock these days.

What's the news for me, Greg? I wish to purchase, brother! My EGR solenoid is fooked so the sooner the better. :)

[GoLfMan]

What's the news for me, Greg? I wish to purchase, brother! My EGR solenoid is fooked so the sooner the better. :)
dang thats a shame! :P

you hear alot more turbo whistle with the delete. It's great :D

just remember that we have the PD150 manifold stock when you go to order

[kaanage]

I have to say I've noticed no heat difference on my EGT's with no EGR, but then my car is getting a lot better cold airflow than stock these days.

I thought that since the EGR is designed to effectively decrease the oxygen in combustion chamber, then increased air mass would also increase the EGT.
But then increasing boost lowers EGTs in an overfuelled diesel....

[Preen59]

dang thats a shame! :P

you hear alot more turbo whistle with the delete. It's great :D

just remember that we have the PD150 manifold stock when you go to order

I'm hearing plenty of turbo noise with this blown soleniod. hahaha.

I better confirm which manifold I have, as it is a bit different to yours I think. Might need to do some-a-measurin'. :)

What sort of increase in HP are you feeling? Much?

[Greg Roles]

Preenster drop Darkside Developments a line in the UK, it seems the Dieselgeek one is very limited in Euro fitment, being very USA specific.

Can you give me the engine code from the Caddy manual?

[GoLfMan]

I'm hearing plenty of turbo noise with this blown soleniod. hahaha.

I better confirm which manifold I have, as it is a bit different to yours I think. Might need to do some-a-measurin'. :)

What sort of increase in HP are you feeling? Much?

is your engine code AXR??

no real HP increase, it just feels more linear again, and smooth. I like it! :cookie:

[Greg Roles]

Getting rid of the EGR flap makes it a much smoother car to drive!

[GoLfMan]

Getting rid of the EGR flap makes it a much smoother car to drive!
sure does! Big fan of the new driving experience

however my only gripe is by getting rid of the flap, shut off is a lumpy affair, scared the crap out of me when I first turned it off, but then I worked it out and it was all ok :cookie:

[Greg Roles]

Man up you big baby.

[GoLfMan]

Man up you big baby.
finnneeee I will :P

[Preen59]

Preenster drop Darkside Developments a line in the UK, it seems the Dieselgeek one is very limited in Euro fitment, being very USA specific.

Can you give me the engine code from the Caddy manual?

Ok will do. I'd obviously rather get it thru you though, dude. Happy for you to contact them if you want the business.

Engine # is BLS according to my rego papers (had them handy).


is your engine code AXR??

no real HP increase, it just feels more linear again, and smooth. I like it! :cookie:

Getting rid of the EGR flap makes it a much smoother car to drive!

Nice! That's what i like to hear!


sure does! Big fan of the new driving experience

however my only gripe is by getting rid of the flap, shut off is a lumpy affair, scared the crap out of me when I first turned it off, but then I worked it out and it was all ok :cookie:

Good to know before I do it. :)

[Buller_Scott]

was it tricky getting the egr motor out?

i might have to do this.

[GoLfMan]

was it tricky getting the egr motor out?

i might have to do this.
nope. The whole thing took about 20mins.

[GoLfMan]

Also a quick note. When you do the EGR delete, blank it off from the exhaust manifold, You can blank it from three different places along the EGR itself. I blanked it from the top and the flex joint on my EGR pipe snapped
http://www.vwwatercooled.com.au/forums/images/imported/2011/10/65bb02b4-1.jpg
There are two coolant hoses that connect to the cooler, when you take the cooler off you obviously have to join them so the coolant continues to circulate. To do this, locate the hose that connected to the EGR from a T-Piece. Take that off and place the elbow hose that connected to the EGR cooler and connect that to the T-Piece. Looks OEM and it works.
http://www.vwwatercooled.com.au/forums/images/imported/2011/10/f0a8dff0-1.jpg
While I was there I cleaned out my intake. Christ that was a messy job!
http://www.vwwatercooled.com.au/forums/images/imported/2011/10/b0b92f2f-1.jpg

[thealienfromuranus]

ive often thought about doing this with my t5, but too nervous. heard stories like it can increase temp and decrease life. does it make any difference to your polo?

EGT should not increase with an EGR delete as replacing the hot recirculated unburnt fuel with oxygen should help the fuel burn more efficiently and lower the intake temp

It also stops build up on the turbo vanes reducing the chances of them sticking and causing over boost

Worth while modification to improve the longevity

[jfoldbar]

ive often thought my egr valve is stuffed, but dont know how to check apart from changing it. if i block off egr, then valve is still there and if its playing up then i may not achieve anything. im wondering if i can replace entire egr valve case with a peice of hollow pipe the same size, and blank off pipe from exhaust?

[Greg Roles]

EGT should not increase with an EGR delete as replacing the hot recirculated unburnt fuel with oxygen should help the fuel burn more efficiently and lower the intake temp

It also stops build up on the turbo vanes reducing the chances of them sticking and causing over boost

Worth while modification to improve the longevity

EGR is there to lower combustion temps. It's all about controlling NOX, and lowering combustion temp by addition of exhaust lowers NOX. More O2, faster flame front, higher temps, more NOX. The reality for a normal car is that you are right, and you don't see any major rise in EGT's, but if you really look into it, that's the theory. In a gasser EGR is about reburning unburnt fuel, in a diesel it's about controlling combustion temps.

Absolutley agree that more O2 from deleting EGR equals less soot, and that's a good thing, especially with a DPF.

[Greg Roles]

ive often thought my egr valve is stuffed, but dont know how to check apart from changing it. if i block off egr, then valve is still there and if its playing up then i may not achieve anything. im wondering if i can replace entire egr valve case with a peice of hollow pipe the same size, and blank off pipe from exhaust?

In the 1.9 pre DPF I believe that is so.

[jfoldbar]

what about 2.5?

[jfoldbar]

finally done it. cant see what all the fuss is though. cant feel any difference at all. it is a good thought though that im no longer sucking up rubbish. do wonder if its normal for egr to have so much oil in it and where does it come from? and also what is the purpose of the butterfly on the egr valve? i noticed it never moves whatever the revs are.

[GoLfMan]

finally done it. cant see what all the fuss is though. cant feel any difference at all. it is a good thought though that im no longer sucking up rubbish. do wonder if its normal for egr to have so much oil in it and where does it come from? and also what is the purpose of the butterfly on the egr valve? i noticed it never moves whatever the revs are.
butterfly is there as a shut of valve for the engine I believe.

[jazd]

do wonder if its normal for egr to have so much oil in it and where does it come from? and also what is the purpose of the butterfly on the egr valve? i noticed it never moves whatever the revs are.

http://ovh.jazdw.net/SSP_368_The_2_0l_-_125_kW-TDI_Engine_with_4-valve_technology.pdf

Enjoy.

[Greg Roles]

butterfly is there as a shut of valve for the engine I believe.

That, and it works to increase vacuum past the EGR inlet, to draw in more or less EGR. It's a restriction, pure and simple.

It is absolutely necessary to do a regen if you have a DPF - GT TDI/Passat in MKV or all MK6 TDI's.

[jfoldbar]

i got thinking, when i done delete, should i have disconnected vacuum hoses from it so butterfly cant work. if it moves after delete engine cant get any air and will choke. what should i do with hoses when i take them off. since they still have vacuum they could suck up dirt if they are just hanging around.

[Idle]

i got thinking, when i done delete, should i have disconnected vacuum hoses from it so butterfly cant work. if it moves after delete engine cant get any air and will choke. what should i do with hoses when i take them off. since they still have vacuum they could suck up dirt if they are just hanging around.

If you disconnect vacuum hoses you should also block them off — quite apart from any dirt (which your engine wouldn't appreciate) the air leakage will upset things no end.

[Evaded Motorsport]

sure does! Big fan of the new driving experience

however my only gripe is by getting rid of the flap, shut off is a lumpy affair, scared the crap out of me when I first turned it off, but then I worked it out and it was all ok :cookie:

Really? I found it to be about the same as normal but mine is fairly rough anyway. I'm getting no bites on selling it so I'm just about to order the diesel Geek turbo kit and a FMIC.

[GoLfMan]

Really? I found it to be about the same as normal but mine is fairly rough anyway. I'm getting no bites on selling it so I'm just about to order the diesel Geek turbo kit and a FMIC.
the 17/22? how much will that turbo set you back? Its got me thinking because my outing at the track the other day left me wanting more power

[Evaded Motorsport]

Nah, going the 1756VK or the 2056VK 17/22 has issues with EMP. Budgeted the next stage of the build. $8,200 give or take lol.

[GoLfMan]

boraparts.com had the 1756vk brand new for $900 or something. Dam cheap for an upgrade!

[thealienfromuranus]

boraparts.com had the 1756vk brand new for $900 or something. Dam cheap for an upgrade!

Doesnt a 1756vk require a custom manifold to fit?

[GoLfMan]

Doesnt a 1756vk require a custom manifold to fit?
nope, these ones are a single piece turbo/manifold unit. Like the OEM ones

[Evaded Motorsport]

1756VK Requires a custom manifold to fit, the 1749VB is a single piece item. the 1749VB off the PD150 can make up to 200hp the 1756VK can make up to 230hp.

[thealienfromuranus]

A hybrid 1749vb is good for 240hp (179kw)

[GoLfMan]

A hybrid 1749vb is good for 240hp (179kw)
where do you get these hybrids?

[Greg Roles]

Talk to your mates at Darkside Developments!

[getjet]

Is it *cough*illegal*cough* to remove the EGR? How do dealers handle it if you get a dealer service (obviously out of warranty)? :emo_baghead:

[GoLfMan]

Is it *cough*illegal*cough* to remove the EGR? How do dealers handle it if you get a dealer service (obviously out of warranty)? :emo_baghead:
yeh probably is illegal, but its for the longevity of the engine. I wouldn't recommend doing it to a car in warranty!

---------- Post added at 12:06 AM ---------- Previous post was at 12:06 AM ----------


Talk to your mates at Darkside Developments!

I will when the time comes.

reply to my PM ya slacker!

[Evaded Motorsport]

Don't even worry about the hybrids. The EGT's and EMPs they produce are ****. Unless you want to pull the head off an ddo some major port work and get a cam in there to get the EGT's back down you are better off going the 1756

[getjet]

Just purchased the required parts to delete the EGR and cooler from my Jetta (darkside kit). Plan to clean the intake manifold and ASV while I'm at it. I shouldn't need any gaskets if I'm careful, correct?

[GoLfMan]

Just purchased the required parts to delete the EGR and cooler from my Jetta (darkside kit). Plan to clean the intake manifold and ASV while I'm at it. I shouldn't need any gaskets if I'm careful, correct?
My inlet mani gasket was a metal one, which is re-useable :) but that was on the Polo TDI which is an 8v. Yours may be different!

[Transporter]

Just purchased the required parts to delete the EGR and cooler from my Jetta (darkside kit). Plan to clean the intake manifold and ASV while I'm at it. I shouldn't need any gaskets if I'm careful, correct?

If you have the rubber oring style gasket in yours, you can put Loctite Maxi Gray on the old oring gasket, but it is better to replace it with the new one (not expensive).

[Greg Roles]

As Miro suggests new gaskets are stupidly cheap from VW, my GT TDI inlet one between the mani and head was only $8!!

That said, if an o-ring looks fine, I just reuse it, so long as it is still round in cross section and sticks out from the face, when they get compressed level they will no longer seal and need to be replaced