EGR should we all be more concerned

[recalibrate_ecu]

Egr

Hi,
Yes, the amount of black greasy 'soot' in the egr system which eventually finds it's way into the turbo can cause a few problems.
Some of you might know when I return later in the year I will be offering a remapping (reflash) service.

I wondered if your cars are under warranty and the turbo fails if the dealer is accepting to replace for free.

The company that is supporting me offers an egr blanking kit and I am considering selling this kit. This problem is widely reported on my forums in UK including seatcupra.net, (golf) mkiv and others.
I wondered if many members here would be interested in purchasing a kit and I could supply either on an individual basis or offer a group buy?

I have 2 pictures of the egr blanking kit for your information:

I managed to get into EGR valve and EGR motor flap section and nearly had heart attack when I saw amount of black sht inside. The car was regularly serviced and clocked 65K in 4years. I cleaned it, but motor was damaged already so the car is back to the dealer.. it must have a catch can otherwise this will happen again. The deposits were 3-4 mm thick and some could only be removed with metal brush. I am considering fixing it and getting the magic catch can or sell the car. It took 2 hours to remove all bolts as two of them were completely inaccessible.

[HiTorque]

As far as blanking kit is concerned I thought it would only be applicable to mkIV or CR generation. mkV with Pump Duze system cannot be by-passed and this I discovered from UK forum as well. I guess ECU remapping won't solve our problem unless you have something to show here..

[Soup Nazi]

Recalibrate ecu
Ok the remap sounds good BUT, what are the changes you propose and how's it done? How much $? Where?

[Buller_Scott]

As far as blanking kit is concerned I thought it would only be applicable to mkIV or CR generation. mkV with Pump Duze system cannot be by-passed and this I discovered from UK forum as well. I guess ECU remapping won't solve our problem unless you have something to show here..

a guy in the polo forum [decat] with a pd130 turbo [96kw za polo tdi] has had it turned down via a tune. i'm gonna be looking to do the same once i sort some other stuff out.

[Ivo]

What are the chemical cleaning options available to clean the intake manifold and egr when still on the car? I dont want to dismantle the intake system and turbo. Just want to spray something in and clean most of the junk out including the soot buildup on the variable vanes of the turbo.

Does the Interject stuff work? Is the Wynns stuff available here?

[HiTorque]

What are the chemical cleaning options available to clean the intake manifold and egr when still on the car? I dont want to dismantle the intake system and turbo. Just want to spray something in and clean most of the junk out including the soot buildup on the variable vanes of the turbo.

Does the Interject stuff work? Is the Wynns stuff available here?

I don't think it's possible without dismantling. All chemical additives might clean injectors, but the issue is with exhaust system and the additives will be burned out before getting there...

[dundee]

Before you buy it, ask them if their catch can has a safety valve, it is important so you don't risk the blowing your engine's oil seals.
I looked at the pictures on their site and it doesn't look like it has and it's not as well made like the provent. IMO.

Hi guys, new to Diesel, wondering who you suggest for a catch-can? Also have no idea how to fit, so will need it fitted as well.

Cheers

Micky

[Greg Roles]

we need a provent / catchcan sticky. Mods??

[gldgti]

is it in this thread... its in yours cog?

[Transporter]

we need a provent / catchcan sticky. Mods??

Here is the link.

http://www.vwwatercooled.org.au/newforum/upload/showpost.php?p=321348&postcount=140

Do write up on your installation onto your GT TDI and I'm sure it gets sticked.

[Greg Roles]

Post 2 I wrote a bit on mine, but there's a great link back to TDI club.

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=13929

[Greg Roles]

I'm about to help Larry put a Provent in his glorious TDI, so I'll do a picture shoot and writeup. Looking forward to doing it a second time, this time I know what to expect and can do a serious job of it.

[tonymaroney]

Stopping EGR

Hi,
I've read through all of this post, and numerous others but I'm still uncertain about whether I can remove the EGR valve in my 2L TDI Golf (2005...so it's the 103kW PD engine without a DPF).
1) Can I replace the EGR valve with one of these straight through pipes (that still have the vacuum hose attachment on the side, and leave the intake flap manifold flap in there):

http://www.egrvalve.co.uk/index.php?page=home

Or will this throw up codes about low EGR flow? Where would those sensors be that detect that low flow, because there is only a vacuum attachment (no electrics) going to the unit I would be removing?
So I'm not talking about just blanking the EGR pipe off, but rather blanking it off and installing a straight-through pipe as well.
Is this going to be a problem on the 103kw PD engines? Some say yes and others so no!!
Thanks,
Tony

[Greg Roles]

Error codes for certain. The O2 sensor in the exhaust will read too much O2 and freak out. You need a "wayne angle block" from VW vortex, or a way to simply space the lambda probe out of the direct exhaust flow. I've heard spark plug spacers work the same. I just got an angle block, it hasn't gone on yet, but the guys in the US have worked out this angled metal block does the trick, and then you can then block off the EGR.

Downside is the 103kw has less heat handling ability than the 125kw, and the turbo's on the 103 have been self destructing due to too high exhaust temps after chipping. Removal of the EGR will give higher EGT's and you at LEAST need a EGT gauge to watch this temp, as anything over 650-700 degrees is considered terminal to turbo's by all the yanks in the know. I've seen 800 degree spikes in my stock 125 which is temporarily into the danger zone.

Few things to consider my friend!

[peedman]

42draft design sell one too which looks a bit nicer in my mind. didnt know that they were using them for the diesels, they are popular on the petrols since they run a pre cat o2 and post cat o2 and a high flow cat disrupts the second o2's reading. anyway back on topic....