Cleaning the EGR and Inlet on a GT

[Transporter]

Is yours 1.9TDI or 2.0TDI and what year?

For 2007 2.0TDI 103kW
Cylinder head to Intake manifold gasket..... p/n 03G129717D
Oring - making it would be dificult - you need the p/n for it.
EGR paper gasket - could be easily made (original package has no p/n and I lost the invoice)

[benough]

Sorry Miro

It an 07 build, 08 spec 2.0L BMN GT Sport.

[Greg Roles]

The gaskets are all o-rings apart from the EGR gasket (and I'd be putting in a 90% blanking plate just quietly ) so there is no need to replace, but I did price the intricate manifold gasket and VW only wanted $6 for it at the time, which seemed far too cheap, should have bought ten!

[benough]

Yeah I got told that on the weekend, to get a reducer.

This is what I have found.

Part Number:028131547B

Below is the original Gasket (Top) and New Gasket (Bottom)



So will this reduce extend the length of time for the car to warm up?

Also will it raise my EGT? (I'm still a touch noob even after reading all your posts)

[Buller_Scott]

Yeah I got told that on the weekend, to get a reducer.

This is what I have found.

Part Number:028131547B

Below is the original Gasket (Top) and New Gasket (Bottom)



So will this reduce extend the length of time for the car to warm up?

Also will it raise my EGT? (I'm still a touch noob even after reading all your posts)

those are questions that i would be keen to know the answer to as well.

i've been really babying it recently - changing gears @ 2,000rpm, trying to maximise fuel economy etc. extending warmup time probably wouldnt matter to me as im not really thrashing it anyway - when i do, that takes place in the hills, which take 45mins to get to anyway, so plenty of time to warm up.

just one additional question for the gurus - if you install this part, will it mess around with the computer / sensors / throw codes / affect the car's driveability? i'd presume that it WOULD increase EGT's as more oxygen = hotter... (that wasnt really a question, was it? )

[Greg Roles]

A total block of EGR will throw the engine light CEL ( I live with it currently ) but it is a warning only and doesn't mess with the normal running of the car. The hole allows enough to prevent the CEL, may have to upsize it a little if the CEL shows up. Just drive it normally for warmup, and even with no EGR and a lot of cold air coming in, I have not really noticed longer warmup times.

Also I've been anxiously watching my EGT's since deleting the EGR inlet, and even with mothballs, I'm not noticing any unusual temps - at all!

I expected higher EGT's with no EGR, but it's simply not happening with normal driving! If you put in a plate with a hole, you will very likely not even notice a change. The benefit is a lot less soot going into the inlet, and that's a huge plus on my books, so I can recommend the hole EGR plate to everyone. Anyone with a hopped up/track/drag TDI should be running an EGT gauge anyway, or at least driving around for a few days monitoring EGT's on VagCom. I'm keen to find a way to delete the CEL, and when I do I'll be sure to let all the oiler crew know!

[Buller_Scott]

if a CEL is the only negative repercussion of running a complete blank off plate, that's nothing - my airbag light has been on ever since i took off the steering wheel like 8 months ago.

this is probably doubling up on questions, but did you notice better response / acceleration / grunty torque, as a result of no EGR, greg?

[benough]

If these gaskets are a couple of bucks, I'll buy a bunch and post them to people.

Off the see my local parts chimp. Will let you know how I go.

[benough]

UPDATE:

At DENLO they are $6.50 each.

I also ordered the side o-rings between the control flap and the valve and a manifold gasket.

The o-rings were similar in price but the gasket was $22 farken!

I've got a 5 day weight from the Singapore parts bin :-/

[jazd]

Info on the 125kW diesel engine if you want to read up on the EGR a bit more:
VW Self Study 368

[Greg Roles]

if a CEL is the only negative repercussion of running a complete blank off plate, that's nothing - my airbag light has been on ever since i took off the steering wheel like 8 months ago.

this is probably doubling up on questions, but did you notice better response / acceleration / grunty torque, as a result of no EGR, greg?

No difference with EGR delete, the drivability difference came with getting rid of the EGR / anti shudder flap, another recommended thing to do, but unplugging that from the loom does indeed put it into limp mode, and throws major errors if you have a DPF when it tries to regen. Am working on that solution, but it is a far harder delete, on the 2.0 at least.

Sort your airbag dude!!

[Buller_Scott]

No difference with EGR delete, the drivability difference came with getting rid of the EGR / anti shudder flap, another recommended thing to do, but unplugging that from the loom does indeed put it into limp mode, and throws major errors if you have a DPF when it tries to regen. Am working on that solution, but it is a far harder delete, on the 2.0 at least.

Sort your airbag dude!!

thanks for the info, greg! those plates might be a worthy little investment from the point of view of less soot in the intake mani.

as for the airbag - i can only really think of one way to test if it's working still, but that might be a tad expensive

[benough]

My reducing gasket has finally come in. I got the manifold gasket as well as the o-rings for the EGR.

I'm going to have a crack over the LWE.

[Greg Roles]

The kick in the nuts is EGR creates more soot....get that limiter on there!

[benough]

I've had my first mechanical set back ever today.

I got all but 1 bolt out of the manifold but I couldn't get the EGR off.

I took pics of the bolts (the upper is a torx and the lower is a hex) but all my by torx/hex bits either slipped or were too big. Which is odd b/c you can undo %50 of a Golf 5 with a T25 bit.

I have the EGR page from ERWIN but it doesn't have instructions, just an exploded diagram.

LINK

Feel like a n00b that it defeated me