Let the tinkering get serious!!....

[Greg Roles]

Geez mate, to keep chickies happy you have to do some stuff for them! Since my last post I did turn my crappy rumpus into a girlie home office, doesn't just happen in a day you know!

Anyhoo, back to the important stuff, here's the turbo to IC roughly fabbed up in place, I could make it a bit "neater" looking, but I've tried to keep the bends nice and smooth all in the aim of flow. Also, the last pic is the IC to manifold roughly fabbed up on the bench, and this goes in once I spend several days fault free with no EGR. Just need to get the lambda probe out, it's in a tricky spot, no doubt VW has a special tool for it.

Benno, the DPF is in for a lot more than that, c'mon, as IF I'd just hollow it out...

[benough]

LOL! Well I'm keen to see what you will be doing then.

Has anyone actually tried gutting their dead one and putting it back in?

[Greg Roles]

Would be fine until the first regen, where it injects extra fuel late in combustion so that it actually explodes in the DPF thus raising the temps dramatically. Add to that the fore and aft pressure sensors would register a fault straight away. It's a pretty clever piece of engineering, tricky to circumvent without coding.

[benough]

Ha! I know VW would have that covered.

But why would it regen if it's not getting the backpressure from a soot level build up in there? I figured with an empty one it would never need to regen.

[Idle]

Would be fine until the first regen, where it injects extra fuel late in combustion so that it actually explodes in the DPF thus raising the temps dramatically. Add to that the fore and aft pressure sensors would register a fault straight away. It's a pretty clever piece of engineering, tricky to circumvent without coding.

If the extra fuel just went straight through there might be some smoke (ugh!), but I wouldn't expect it to explode (as a rule diesel burns rather than explodes — that's why it needs such high pressures to ignite in the engine.)

Besides, I'd have thought that if one bypassed both sensors with the appropriate resistance, regen should never be triggered.

[h100vw]

Regen occurs in response to a partially blocked filter/change in back pressure. Eventually they will all get blocked. Explode isn't the best word to use but the exhaust temps gets high enough to burn off the soot and turn it to ash.
Gavin

[Transporter]

If the extra fuel just went straight through there might be some smoke (ugh!), but I wouldn't expect it to explode (as a rule diesel burns rather than explodes — that's why it needs such high pressures to ignite in the engine.)

Besides, I'd have thought that if one bypassed both sensors with the appropriate resistance, regen should never be triggered.

It is actually the temperature of the compressed air in the cylinder that ignites the diesel fuel. If the compressed air would be cold, there would be no ignition and engine would not start.

Back to DPF.
ECU monitors the sensors on the DPF and if the data don't much fault code is logged and ECU will do what is programmed to do. That's why it needs to be reprogrammed.
Unless, someone tinkers with the sensors and finds the way to delete them (or leave them there) and use just hollowed DPF box without the need for reprogramming, the advantage would be, if you for some reason have to install DPF back, than you can do it very quickly at home - no need for VW specialist.
So, yeah Greg what ever you do there I wish you good luck, I'm sure you will keep us posted.

[Greg Roles]

Sorry all you word nazi's , I meant "fuel is ignited" in the DPF during regen, and this is from the VW service bulletin I have on DPF's. If the DPF doesn't do a regen due to driving in a set timeframe / km's, it's programmed to do one anyhow. Even if you bypass the sensors, it's going to default to a set km regen schedule.

[benough]

Thought from this morning.

Could you potentially gut your DPF when it carks it and then just get the coding from CC/Gavin to trick the ECU rather than having to buy the downpipe?

[Greg Roles]

Not at the moment, the JBS downpipe is required to get the tune. It's a CC thing.

[benough]

Business arrangements aside though, it should be possible right?

[Greg Roles]

Absolutely. You'll have to wait till Custom Code UK decide to relax their laws, or other, long term successful DPF off tunes come out.

[benough]

Food for thought. DPF cars here haven't come out of the three year need for a rego check yet. I got mine in Feb 08 so I'll probably be first. The muppet around the corner won't know what a DPF is and if it's missing or not!

[h100vw]

JBS/CC have done modified standard pipe tunes but TBH when you do the maths. Taking the std pipe off and gutting it, it's not far removed from going with the Milltek.

The software would most likely be the same price. I'd want to check with the UK to be 100%.

You also get a fair bit more power out of the Milltek.

Gavin

[Greg Roles]

Gav's right, a big volume right out of the turbo would cause exhaust gas to expand and slow markedly, and cause a congestion effect. The DPF intact would probably be better!

Anyway, back on topic, this arrived in the mail on Friday, thanks Ryan! I've now a second DPF to hack up : )

Doesn't look like $4500 odd....