Post by: jason_rmh on September 05, 2013, 11:23:20 pm
My car has recently been experiencing juddering problems when cruising as constant speeds, mostly around 30 - 40 mph. Also, black / grey smoke from the exhaust at low speeds and when reversing.
No error codes logged in VCDS. I noticed a build of oil residue around the EGR valve and had suspected it for a while. So time to change it...
This guide is for the BKD (TDI 140) engine but may also be applicable to the BMN (TDI 170 engine).
Update: EGR cooler on the PD 170 (BMN) engine is mounted underneath the exhaust manifold and much more difficult to remove.
I have checked to make sure the details are correct, but if anything is wrong, or there is a better way of doing things, shout up and I will update the guide!
Whats the EGR?
EGR stands for Exhaust Gas Recirculation.
Most modern cars are fitted with an EGR system to help with emissions and economy.
The EGR system consists of the EGR valve which directs exhaust gases from the exhaust / turbo to the inlet manifold, and a control valve which actuates the system according to engine load and speed.
On engines with a vacuum operated EGR system (BKD), the control valve is a solenoid valve which opens vacuum from the inlet manifold to the EGR valve actuator, when the solenoid is energised by the ECU.
Where a re-circulation potentiometer is fitted (BMN), control of the system is directly from the ECU which activates the control motor.
The EGR valve is mounted to the inlet manifold and is connected to the exhaust manifold by a metal pipe and a gas cooler (EGR cooler).
The EGR cooler uses coolant from the engine cooling system to cool the exhaust gases before passing them to the inlet manifold.
The main reason for EGR is to reduce combustion temperatures so that NOx (nitrogen oxided) emissions are reduced. In the UK, NOx is not measured during an MOT so is not actually required.
The EGR valve only operates at idle and during cruising. The EGR valve does not open under heavy load and therefore, you will not be burning exhaust gasses while at wide open throttle.
The EGR valve also helps your engine by richening up the air/fuel mixture but without additional fuel. It does this by reducing the amount of oxygen in the cylinders and thus the amount of fuel needed to keep a sane engine temperature while at cruising speeds. This reduces the amount of fuel your engine needs to burn when power demands are low.
Whats does this mean?
On new cars (less than 3 years old, this means exhaust gases are recycled through the engine, meaning less emissions from the exhaust as more is burnt off in the engine, improving fuel economy, using less fuel at low speeds.
However, as the car gets older, these exhaust gases clog up our supposedly clean inlet manifold. Im not sure if it will cause any performance issues though.
There is all sorts of arguments before and against on the internet!
Regularly, EGR valves are known to fail due to build up of carbon deposits, as has mine, and the cost of removing it is often cheaper than replacing with a new EGR valve which is likely to fail again in the future.
Are there any adverse affects if I remove my EGR?
You are removing the nasty exhaust gases from clogging up the inlet, leading to a healthier engine. If you have a DPF and remove that also, you will see a performance improvement.
You will get an engine management light on the dash which can be mapped out (more on that later).
You will probably not get any noticeable performance improvement if only removing the EGR.
There is no harm in removing it, and it will not affect MOT.
However, Im not here to argue about the reasons why... I just want rid... so here goes...
Duration
This took me about 3 hours for EGR valve and cooler, while taking photos!
As with anything you havent done before, allow your self plenty of time and ensure you have the correct tools before you start...
Tools you will need:
For EGR Delete:
- EGR Delete Pipe (Allard or Darkside?) Approx £80
- Torx bit set (T25 / T30)
- Small ratchet & socket set & extenstions
- Allen Keys
- Hose Clip Pliers or large grips
- Flat blade screw driver
Addition parts required for EGR cooler delete:
- Water coupler (EGR Cooler Delete Pipe) 3B0 122 291 B approx £8 from VW
- Remote Hose Clip Pliers
- Hose Clip Pliers or large grips
- Spare length of hose (read EGR cooler delete guide (below) for guidance
- Container to catch leaking coolant
- New coolant from VW / motor factors to top up when finished.
EGR Delete Pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fpp2%2Fax_jas%2F01a_zpscebb44bd.jpg&hash=55a6ac074d31a33ced70bbba3582f75eee465ada)
- A - EGR delete pipe
- B - EGR blanking plate
- C - EGR Blank plate mounting nuts
- D - Boost gauge take off tap (for connecting a boost gauge)
- E - grub screw (if boost gauge not fitted, blank the hole with grub screw)
EGR Cooler Delete Pipe (3B0 122 291 B)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F03_zpsa89e96a6.jpg&hash=7a5b722821f9e5274ead3fc2f5e44eed1e2f8470)
Remote Hose Clip Pliers (to remove band clamp on turbo / intake hose)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F00a_zps70575089.jpg&hash=75908ac2b3c79d48646ffe60356973f6adc5a9e2)
NOTE: You do not have to remove the EGR cooler, and it can be done later if you want. Once the EGR valve is removed, the cooler is redundant so not required.
This guide details removal of both parts.
EGR System
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F04a_zps6537bd4f.jpg&hash=42ca2326df1b39d38efb28cbe4c1cfc479ba3b34)
- A - inlet manifold
- B - EGR vacuum hose
- C - EGR valve
- D - Anti Shudder Valve (ASV)
- E - inlet pipe
- F - inlet / exhaust manifold connecting pipe
- G - turbo intake pipe
- EGR Cooler is not picture, but is situated at the back of the engine, underneath 'G'
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EGR Valve Delete
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Remove engine cover
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F05_zpscb882565.jpg&hash=a42a0325291926bb82101ce98a7403dc61c54198)
Pull cover upwards, off rubber grommets on front left and right and rear right (as you face the engine).
You can then slide the cover off the rear left mounting.
Engine cover removed
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F06_zps687fc375.jpg&hash=deeb502cbc5b07097b8ae8d1e7672a5be68a424f)
You will now need to remove the airbox. I have an APR intake and so will not detail airbox removal here....
Here you can see the EGR valve connected to the inlet manifold.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F07_zps8c9e5213.jpg&hash=d1cad16bd8fb0c27573ead51a1bf2e723ff52637)
Disconnect MAF sensor connector plug.
Pull up on the tab (arrowed) while pulling up on the connector.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F08_zps9dc6de70.jpg&hash=fde54d3079cf86033f20b785766436fc001aa6b5)
Remove band clamp from turbo intake pipe.
You can use pliers for this but will need either large grips or hose clip pliers to get it back on.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F09_zps3593d3e1.jpg&hash=c8d25d814e6d9b04be84f0673df2fd85b0cc8f19)
Remove MAF assembly.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F10_zps76756175.jpg&hash=c672f5f0dd6cfd2cd46155d466c78f5185b8ce9b)
Release hose clip on rocker cover breather hose and disconnect breather hose.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F11_zps0d471d46.jpg&hash=b9a903d91459dc7db278c550552df6414b0ce68d)
The turbo intake pipe is secured to the EGR cooler mount by a T30 torx screw...
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F13_zpsca71b30e.jpg&hash=1107c7ecf95fd88141a447d7aa5f40bfe3fc5b32)
Remove the T30 screw, to free the intake pipe giving better access to the EGR cooler.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F14_zps252b62ae.jpg&hash=d00ed61063a4f0bc5b3a92bb3bb5ee4e7f0f858e)
Below the turbo intake pipe you will see the inlet / exhaust manifold connecting pipe bolted to the side of the EGR cooler by 2 x 6mm allen bolts.
Remove them to release the pipe from the cooler.
Be careful to recover the gasket, dont let it drop down the engine bay!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F14a_zpsabd9760f.jpg&hash=1051d8e29ff3942b478c8d9cc32ff028ab2a0787)
The inlet / exhaust manifold connecting pipe also connects to the side of the EGR valve by 2 x 6mm allen bolts.
Remove them to release the pipe from the EGR.
Be careful to recover the gasket, dont let it drop down the engine bay!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F15_zps70f72d33.jpg&hash=78352dbe99d408349bc2f416b36ffb4f34b4261b)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F16_zps7419f64c.jpg&hash=f0904a43cb17b845fdf5d0f258d419de46dbdcc0)
The inlet / exhaust manifold connecting pipe is finally secured to the side of the engine by a 10mm nut which needs to be removed I couldn't picture this, but see the ratchet for an idea of location...
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F16a_zps9f8abab2.jpg&hash=9a181e66490ee4b43d71e1d27d856da1fa08b71b)
The inlet / exhaust manifold connecting pipe should now wriggle free and can be fully removed, in the direction of the airbox, navigating it around the various pipes to get it free.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F16b_zpsee9a997e.jpg&hash=6ee6de9a33a922863ea049a7024c8e74ef383f44)
The inlet / exhaust manifold connecting pipe, gaskets and nut..
NOTE: there are 2 gaskets and 4 bolts not pictured here.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F16c_zpsc933f842.jpg&hash=8a03abf7c24261b85ebbcc610a9a8bb7b073b2aa)
Now to remove the inlet pipe.
Prise out the clip with a flat blade screw driver. The clip does not need to be fully removed.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F17_zps8d45a2f5.jpg&hash=8dbcd6148c9fa72d6e1f4b4cbee0ccffc03c9098)
Pull down on the pip to free it from the ASV.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F18_zps8b8c8dc3.jpg&hash=3943bc70b60105d1e55695d6b3528b44e25bd3fa)
Now to remove the EGR Valve
Remove the connector plug from the ASV.
The EGR Valve is secured to the inlet manifold by 3 5mm allen bolts which need to be removed.
One is a little tricky to get to, and is longer than the other two, see pictures...
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F19_zpsdaf18e51.jpg&hash=a92f4603ad55394705364a34476fff94033ebb34)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F20_zpsc6fc630e.jpg&hash=2978151423b511021774c53b48dc93e0087b9e3d)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F21_zps3063b4bf.jpg&hash=fe5461864a6e29bb8d7ac876a408c0c9e6ba0802)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F23_zpsdddcf4c7.jpg&hash=36d52a55c3a921531222d73e58081c9b7005d88a)
The EGR valve and ASV should now come free and can be removed from the engine bay.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F24_zpse16b0a28.jpg&hash=56e20160dd0f4f09a70eec888b2d9aea9cdbacb9)
Notice the huge build up of carbon and sludge!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F27_zps7cc84748.jpg&hash=2b668e4de9b7441baf7236fef71a29c1a3727ae1)
The EGR is connected to the ASV by 2 x 5mm allen bolts. Remove them and separate the two units.
The bolts will be required shortly.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F28_zps9ef5dccd.jpg&hash=c04ba57fca8d3bf9d7a4de12d0cc2d105b22689a)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F29_zps94868869.jpg&hash=0aaa2c2792536bb9d1c5a4c478b14371bddc0c29)
Take this opportunity to clean the ASV. I used intake cleaner (aerosol) but WD40 might work also, with a rag.
Ensure it is clean and dry once finished.
You might also want to clean your inlet manifold, but I recommend removing it first, which will be covered in a separate guide...
Notice the build of carbon there also.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F31_zps682372e0.jpg&hash=54a665d9bdc0e0ca4cf91bf3cd34585f44b93f9a)
Grab your EGR delete pipe!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F30_zps5382f3f0.jpg&hash=bd51730e10206f3918b26deff342a0afbb776ec7)
Connect the EGR deete pipe to the ASV.
NOTE: only the two smaller 5mm allen bolts will be fitted now, the 3rd longer bolt connects the ASV and EGR delete to the inlet manifold.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F33_zpseba8c4ca.jpg&hash=21a5b22f3b3797a6ccdfee2bb70a93214e5136d0)
Ensure the supplied O ring is fitted to the top of the EGR delete pipe.
Also fit the small grub screw to the delete pipe, this blocks a hole that could be used for a vacuum hose to run a boost gauge. Easily removed later on if you decide to do that.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F34_zpsecbbeff9.jpg&hash=0356259453773c1becc95c294f49faace373e46f)
Fit the complete EGR delete / ASV assembly to the inlet manifold, with 2 small 5mm allen bolts and the longer allen bolt pictured above.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F35_zps0b3b1184.jpg&hash=be6e286a65068a5cf6649cd8536948a909d21983)
The EGR vacuum hose now needs to be plugged. Use one of the spare 5mm allen bolts, secured with a cable tie. Any similar sized bolt will do.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F36_zps36b5e7a3.jpg&hash=45d668cc7be8386d852923a2d81eb9fe0b267ce6)
I used another cable to to keep the vacuum out the way.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F36a_zpsd5d54748.jpg&hash=5ad79797772e0d18259da94eebb7ed7ed1264e12)
Reconnect wiring connector to ASV.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F37_zpse01e85f0.jpg&hash=d70805829e2838c7e35784905e59c4b5c6bb3830)
NOTE: This step is only required if you are not removing the EGR cooler at this stage.
If you are removing the EGR cooler now, do not fit the blanking plate.... read skip to the EGR cooler section of the guide!
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Now to plug the hole left by the inlet / exhaust manifold connecting pipe using the EGR blanking plate.
You will need the EGR blanking plate from the EGR delete kit, 2 x 6mm allen bolts and a gasket from the inlet / exhaust manifold connecting pipe.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F38_zps3d193853.jpg&hash=1d7fa95bf9fded8242dd40b9b19aa006e67a380a)
Secure the EGR blanking plate to the side of the EGR cooler.
Ensure the gasket is fitted correctly.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F39_zps98dd24a6.jpg&hash=d89bd0807ac0d9d10f43acb6b3178c97525b55f6)
You should now be left with the EGR valve and inlet / exhaust manifold connecting pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F40_zps521515b6.jpg&hash=2d7ae6d30eed70a30acd6ef33d59e478c88d150c)
Skip to the All done? section below! :congrats:
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Removing the EGR Cooler?? Read on...
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EGR Cooler Delete
-----------------------------------
This EGR Cooler delete guide relates to the PD 140 (BKD) engine.
The EGR cooler on the PD 170 (BMN) engine is mounted underneath the exhaust manifold and much more difficult to remove, this guide will help, but will not be exactly the same setup.
If you have previously remove the EGR valve and returned at a later date to remove EGR cooler, you will need to follow the start of the EGR Valve delete guide to remove the following:
- Airbox
- MAF Assembly
- turbo intake pipe retaining screw
To give access to the EGR cooler I would advise removing the turbo intake pipe...
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F41_zps677b2b07.jpg&hash=ccfd5b869d5723251f79c7beebc2cbc1d3f0ce36)
Firstly, remove another T30 retaining screw which secures the intake pipe below the left bottom corner of the EGR cooler. I could not picture this, but see a picture of the pipe once removed to note the location of the screws:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F42_zps3fc7a1a7.jpg&hash=cbaa868b06014e53f0ca6d66b5281d0029eeb1e5)
Once the screw is removed the only thing securing the intake hose is a clamp where it meets the turbo....
To access the turbo...
Jack up the front of the car and secure on axles stands.
Remove the under tray, secured with T25 screws and 3 x 10mm bolts.
To improve access, remove the connector plug from the sump
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F43_zps43e75d8c.jpg&hash=ca2019ee5a6e6a239393c7caa09276dc9b1c66cd)
Get under the car and look up past the drivers driver shaft to see the turbo.
Locate the band clamp securing the turbo intake pipe (E). This is the same pipe that runs along the top of the EGR cooler, labelled in a the diagram at the start of this guide.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F43a_zps42487d45.jpg&hash=9bb029df00f20676e7e23522b5990d4d52ea251c)
To remove the clamp you will most likely need a set of remote hose clip pliers, shown below with the clamp fully removed, for illustration:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F43b_zps2c94681a.jpg&hash=35119948265738b5de2a0cc54e4fb64e22c69ae5)
With the clamp unsecured, pull the intake pipe from the turbo and withdraw the pipe up through the top of the engine bay.
The EGR cooler is secured by 4 x 6mm allen bolts. Some of them are are difficult to see:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F44a_zpsea633c06.jpg&hash=5b2686c81cb8195f70b8b5a15b6ed4d4819f8e64)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F44b_zpsf02177d6.jpg&hash=a68a671cf69f13fbf1d8ca94edc6eff9821b15da)
top left:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F44c_zps0bb4298b.jpg&hash=4746fa9941920df66d99e02a3f3abc044e11d640)
top right:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F44e_zps64f0f22f.jpg&hash=5a8a3ee3422e9f3f7937ff301886b584ae22c762)
At the back of the engine bay, underneath the EGR cooler is a pipe connecting the EGR cooler to the exhaust manifold. This is secured by 2 x 10mm bolts that need to be removed.
Once removed, the EGR cooler will be free to pull off the exhaust / turbo manifold.
NOTE: It will still be attached by coolant hoses! Be careful to recover the gasket, dont let it drop down the engine bay!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F45_zps3b25dfbe.jpg&hash=98b78aa36dc8b0951d5eb862cd2aeb3589387548)
Disconnect the vacuum hose that runs from the turbo boost pressure solenoid to the EGR solenoid on the left side of the exhaust manifold.
The boost presure solenoid is a black box mounted on the bulkhead, near the battery, with several vacuum hoses going to/from it.)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F46_zps5dd95dd4.jpg&hash=b66e9e309a3990197cf37e5b776561d0b6710720)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F47_zps618b0edd.jpg&hash=5bb92b0dca0015bac40a026d0a0cf26f4d282ee6)
Boost presure solenoid vacuum hoses.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F48_zpsbefd6dcd.jpg&hash=93a5030d2cfba8e9da19ae0c830053a786fc36c5)
Take notes of the coolant hoses connecting the EGR cooler to the engine coolant system.
NOTE: Coolant will leak when these pipes are disconnected, unless you clamp them with hose clamps. If you dont have hose clamps, try and catch the coolant in a container, or let it drain to a containr on the floor.
If left to drain, all coolant in the expansion tank will drain out, but engine and radiator will remain filled.
Disconnect all hoses pictured and removed EGR cooler from engine bay.
You may want to put the EGR cooler in a bucket / container as it will also be filled with coolant.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F50_1_zps8ac166f3.jpg&hash=0f1fadcab25049adc3638f2abe684bfa4d8f8628)
Now there are several hoses to reconnect to complete the coolant system.
Release clamp on hose (B).
Release clip on coupler (C) using flat head screw driver and pull the right angled water coupler to release hose (A) from the bulkhead.
This hose is no longer required.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F49a_zps5cd2edd9.jpg&hash=44a9e72d6e42d7762de64f29d12b3158cc1e0901)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F51_1_zps823dcb4b.jpg&hash=ec3ccdd59d99c718d232a0a241223d3cba6750f8)
Using the new EGR cooler delete pipe, which is simply a slightly different water coupler (straight, not right angled), connect to hose (B) which comes from the engine and secure with hose clip.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F03_zpsa89e96a6.jpg&hash=7a5b722821f9e5274ead3fc2f5e44eed1e2f8470)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F52_zps1fb1271c.jpg&hash=b01425cdff8f4186c1b65119111ba0935abcd26f)
Push hose onto bulk head connector, you will have to slightly twist the pipe, ensure not to kink it. Once secure, push retaining clip in, to secure the pipe in place.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F53_zpsfa00636d.jpg&hash=a0f29b2cab3f1f933ef8b52ee91ddf83fcaca17f)
Now to bridge the gap left by two smaller water pipes which would originally run to / from the header tank.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F56a_zpsfa7046fa.jpg&hash=c7c157bdd31d124c7cedb7d7021faa3ce598b026)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F55_zpsa05140ea.jpg&hash=81eccba62e0aef88d39e1ce348f0b54d1a233b0b)
For this you will nee a length of hose of similar diameter.
You could use part number: 1K0 121 447 S (coolant hose) from VW which is the same hose running from the header tank.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F00c_zpsadf67960.jpg&hash=7958180e3535c751aa8d09b6763602990cebaf3e)
Or you could reuse one of the small hoses removed from the egr cooler, but this will mean cutting them and they will not be able to be used if you want to return to standard.
Ensure all hoses are secured with the original pipe clamps.
My spare piece of hose found in my garage, with pipe clamps removed from EGR cooler.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F54_zpsdbe356cb.jpg&hash=99e8a0ac6a1cb174f69fe72576103743edbfaab6)
The hose will be used to bridge the two smaller water pipes.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F57a_zps93e48682.jpg&hash=e72019d213b1c94c016959c23327e02ff6ebf883)
Now to plug the vaccum hose that originally went to the EGR solenoid. Plug it with one of the spare 5mm allen bolts.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F58_zps06f073c2.jpg&hash=f106c7d949b1c904103c3e783aaacfd9bba14904)
I cable tied this to the Boost presure solenoid mounting bracket to keep it out of the way.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F59_zpsd3e79efd.jpg&hash=66cd838bd313b231a4f1ddc58ce4762120e885aa)
Finally, the EGR blanking plate can be fitted to the hole left on the exhaust manifold.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F60_zpse047b04f.jpg&hash=bb73896272211350354f986f0d303d932c8cbfaf)
Ensure the gasket is refitted.
You can secure using the original 10mm nuts or use the new ones supplied with your EGR delete pipe.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F61_zps1db95970.jpg&hash=ec508b0dbd93aa8c1236d0c61b5a16fbcf69f27e)
You should now be left with the EGR valve, EGR cooler and various other parts removed that are no longer required.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F62_zpsd3455a00.jpg&hash=a293156a9891c2f5be2ed07454ff57ab83d9db30)
Refitting
As in the haynes, refitting is a reverse of removal :grin:, except you havent got as much to refit
For me the main struggle was getting the band clamp back on the turbo intake hose due to restricted access.
Aside from that everything else was relatively straight forward!
All done?
:congrats:
Once everything is back together and car is lowered to the floor, double check:
- All coolant hoses connected
- All coolant vacuum connected or plugged
- Header tank topped up
- NO TOOLS LEFT IN ENGINE BAY
Start the car and let it idle. CHeck around and under the engine bay for leaks (air and water).
Let the engine warm upto temperature (90 degrees) after which point the fans should cut in.
Monitor coolant and engine temperature.
:party:
Take the car for a drive. At somepoint the engine management light will illuminate and MFD (highline) will show a fault:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FGuides%2FBKD_EGR_Delete%2F63_zpsd662fc5c.jpg&hash=9a01ca068ae6f5d8bfcaf941680e9689af9d44d2)
This is because the ECU is trying to open / close the EGR valve and is registering that its not there.
You will need to get the EGR mapped out of your ECU to remove the light (approx £70 at a tuners).
Thanks for reading and good luck!
:happy2:
Post by: jason_rmh on September 05, 2013, 11:32:43 pm
Be aware if reading this on tapatalk, some of the forum formatting isn't coming out properly so just read the PDF ;-)
Jas
:party:
Post by: marko on September 06, 2013, 12:04:01 am
:happy2:
Post by: Matto on September 06, 2013, 09:47:52 am
I spoke to Darkside Developments about removing mine and they told me that on the BMN its a lot of work to remove for the sake of removing it. I would however go to the trouble if it started to leak like they can do.
Great guide for those out there who have been wanting to do it though. Might be worth getting Rich to add it to the "How To" thread :happy2:
Post by: Shorty on September 06, 2013, 09:58:35 am
Good write up mate!
Post by: jason_rmh on September 06, 2013, 11:34:27 am
I struggled to find a decent guide on egr cooler delete so thought I would figure it out and write one ;-)
Post by: jason_rmh on September 06, 2013, 11:55:42 am
Did you do as I have done?
I've got a better way of doing it, connecting straight to the header tank that I want to try out.
Jas
Post by: doylebros on September 06, 2013, 02:35:06 pm
Post by: Shorty on September 06, 2013, 05:16:50 pm
Shorty, how did you bridge the small water hoses?
Did you do as I have done?
I've got a better way of doing it, connecting straight to the header tank that I want to try out.
Jas
I did the same as you have done, but not that happy with it being honest, the silver pipe that runs across the top of the rocker cover just doesn't sit right does it?
What's your idea?
Post by: b9rgo1234 on September 06, 2013, 07:01:51 pm
Post by: four! on September 06, 2013, 09:51:31 pm
Im interested to see who you choose for your remap and to disable the egr system.
I've also got the bkd engine in mine and there is slight surging when on cruise at 80 in top gear. Im sure its something to do with the egr system so was going to try a remap with egr software delete then if it fixes it get rid of all the parts.
I would like a remap which is quite lively low down so you can feel the difference but don't want it to hold loads of boost at high revs to try and preserve the turbo a bit :)
Leaning towards the r tech one at the mo
I think shark can do egr delete and darkside :smiley:
Post by: jason_rmh on September 07, 2013, 02:09:12 pm
I did the same as you have done, but not that happy with it being honest, the silver pipe that runs across the top of the rocker cover just doesn't sit right does it?The silver pipe is pretty redundant so my my idea is to extend the pipe from the header tank over the back of the engine bay to the small black pipe directly, and remove the silver pipe altogether?
What's your idea?
If you look at where the hoses are routed it makes sense.
Fantastic write up! Thanks for taking the time to do it :happy2:No problem! Was quite time consuming to annotate the pics and write it up, but I couldnt find a guide so it will hopefully help out other members!
Nice guide :)
Im interested to see who you choose for your remap and to disable the egr system.
I've also got the bkd engine in mine and there is slight surging when on cruise at 80 in top gear. Im sure its something to do with the egr system so was going to try a remap with egr software delete then if it fixes it get rid of all the parts.
I would like a remap which is quite lively low down so you can feel the difference but don't want it to hold loads of boost at high revs to try and preserve the turbo a bit :)
Leaning towards the r tech one at the mo
I think shark can do egr delete and darkside :smiley:
To be honest, i'm toying with doing my own EGR delete map... if I manage it, I will post up :jumping:
My car is already remapped by CC Tuning in Burton on trent.
http://www.cctuning.co.uk (http://www.cctuning.co.uk)
Friendly, knowledgeable and very reasonable pricing.
We've all heard great things about r tech, that's probably where I'm heading next after the next engine mods are done.
Thanks all for the feedback, good to know the effort was worth while :jumpmove:
Jas
Post by: Matto on September 07, 2013, 04:44:07 pm
I think I will be using CC to have mine done soon and get rid of the Shark software.
Post by: jason_rmh on September 07, 2013, 05:10:31 pm
You not happy with shark map?
Post by: AndrewJB on September 07, 2013, 05:14:39 pm
I think I will be using CC to have mine done soon and get rid of the Shark software.
Any reason why? Ive seen Chris mapping cars at a few of the TDISport RR days they seem to make good numbers on his RR
I felt his RR was under reading when i had my Ibiza RR'd there it made 105-110 on 3 sets of rollers then made 93 on his.
Post by: Matto on September 07, 2013, 06:07:21 pm
Post by: AndrewJB on September 07, 2013, 06:32:57 pm
I had the Stage 2 (Made 216bhp) and Stage2+ (228bhp) map on my PD170
Stage 2 smoked but was still legal levels, Stage2+ was totally illegal
Post by: vRSAlex on September 07, 2013, 10:30:44 pm
Great write up.
Post by: Andy on September 07, 2013, 10:37:34 pm
Post by: jason_rmh on September 07, 2013, 11:10:20 pm
That long grub screw has a hole down the centre of its. Its in the kit to use for the boost gauge tap.Ahhh... So I shouldn't use it to blank off the vacuum hose then. Lol.
Great write up.
What do you normally block the vacuum hoses with?
Cheers!
Jas
Post by: AndrewJB on September 08, 2013, 07:15:25 am
Post by: vRSAlex on September 08, 2013, 09:30:31 am
There is usually a smaller grub screw which is sealed to go in there
That one is for the delete pipe.
Just use a grub screw without a hole down it.
Post by: jason_rmh on September 09, 2013, 11:13:11 pm
- EGR vacuum pipe
labelled parts of the EGR delete kit
mentioned egr cooler differences for BMN (PD 170) engine.
:happy2:
Post by: Biano44 on September 14, 2013, 08:16:27 pm
I still think I'll be taking mine to Alex though......Far easier.
Ta
Matt
Post by: slizza786 on February 16, 2014, 08:18:27 pm
Some stuff that were not pointed out in the tutorial were some hoses connected to the egr and maf pipe that needed to be taken off but they were no problem at all. I would also recommend taking off the cooler and this allowed alot of extra space and ten mins to take off. Also i recommend using a proper allen bolt kit with extenders and proper wrenches and standard allen keys are a b*tch to use!
some have said that only cleaning the egr and avd will not show much of a difference in performance but i beg to differ. I say a change in pickup, high torque on lower revs so really pleased for a job that cost me £7 to do.
Next job will be to clean the turbo vanes with the Mr Muscle trick as this is proven to help the performance of the car ALOt aswell as clean the turbo for only £4!!
This helped solve my P0401 error code.
Once again fantastic thread!!!!
Before
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_143834.jpg&hash=06ca1a4114f48771b1cfa15dc6c90473a474eeea)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_150730.jpg&hash=e0c9a2e63b65ed51382b25791841e05c087d9f90)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_150734.jpg&hash=7e2e4d5e783a02d8e4098a41e3c0995cfa459826)
After
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_153505.jpg&hash=0d41f968489bc894b50f890d6ddafe3493c482c1)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_153530.jpg&hash=7a1140ecb0674ea3c254fcf4a708f7026b08c78d)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_153909.jpg&hash=d2a2773a295547fbfa79defdad5bf59ef6638663)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fbb175%2Fslizza786%2F20140216_154622.jpg&hash=a75357240333efed6a29ed8d5904ae5e436b096b)
Post by: Sjw_Vw on September 06, 2014, 10:46:24 am
Post by: Stirks on October 08, 2014, 07:39:01 pm
Post by: jason_rmh on October 08, 2014, 07:56:28 pm
On the BMN engine isn't the EGR controlled by the ECU? I don't seem to have a vacuum pipe just a plug plugged into the side of the EGR valve. I'm a bit worried about what to do if I delete mine. I read it can send the car into limp home mode.It is controlled by ECU on the BMN engine, I'm not 100% sure of the answer regarding limp mode.
Dark side Developments may be able to answer.
Alternatively, you could try unplugging the connector and see what happens, if you have the means to clear the fault code afterwards?
Jas
Post by: Matto on October 08, 2014, 08:00:41 pm
On the BMN engine isn't the EGR controlled by the ECU? I don't seem to have a vacuum pipe just a plug plugged into the side of the EGR valve. I'm a bit worried about what to do if I delete mine. I read it can send the car into limp home mode.
Yes it is. You will have to have it mapped out.
As @jason_rmh (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=4481) has just said you will get a fault code. I used to get one as it know it has been unplugged but was removed in the mapping I have.
Post by: murph81 on February 15, 2015, 02:26:04 pm
Post by: Andy on February 15, 2015, 03:00:21 pm
Post by: simon0014 on February 18, 2015, 11:24:15 pm
Post by: ant3b on May 07, 2015, 10:05:02 am
Could i do this on my audi a4 2.0 TDI i have been through about 3 coolers now in 2 months...
I just want to remove the cooler and blank the egr? would this affect my dpf?
thanks
Post by: jason_rmh on May 07, 2015, 12:49:22 pm
It won't affect your DPF.
You can use this kit if your engine is BMN / BKD:
http://www.darksidedevelopments.co.uk/products/1-9-8v-pd105-2-0-16v-tdi-pd140-pd170-egr-cooler-delete-pipe.html
Post by: andyb616 on May 28, 2015, 08:06:16 pm
My 2.0 tdi BKD 06 golf today on the way to work started whistling at my like a kettle and loss of power. After having a good rummage around I have found that one of the pipes from the EGR cooler has blown a hole in it - on the flexi section.
Here are two links to your pics showing the offending pipe
- http://s392.photobucket.com/user/ax_jas/media/Guides/BKD%20EGR%20Delete/44b_zpsf02177d6.jpg.html
- http://s392.photobucket.com/user/ax_jas/media/Guides/BKD%20EGR%20Delete/44b_zpsf02177d6.jpg.html
The small metal pipe with the flexi section when I reach round the back/top of the engine I can feel one of the 'bellow' like sections has torn open and all the gas is leaking badly - so figured this is causing the whistling noise and why I have no boost.
My question is, if I follow your guide and just do the EGR delete with the Darkside kit or the allardaluminiumproducts kit will this correct the issue? As I know the pipe is technically part of the cooler section. But I figured if the cooler isn't getting fed due to the EGR delete it won't have any gas to leak?
Or am I being a tad optimistic and will I need to remove the cooler too? Just I don't have the tool to remove the hose clamps, and would like to keep costs down and just get away with the EGR delete if possible?
Many thanks!
Post by: andyb616 on June 02, 2015, 07:12:23 pm
Thanks for the guide again
Post by: schumacher_peng on September 29, 2015, 02:42:11 am
Is it possible to delete EGR/EGR cooler from my 2004 mk.5 2.0 FSI?
Which kit should I get?
I don't want to just blank it but a complete delete. Any tips?
Post by: JoeDarKa on February 15, 2016, 02:34:14 pm
Post by: jason_rmh on February 15, 2016, 03:06:20 pm
Post by: JoeDarKa on February 16, 2016, 07:04:05 am
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fq739%2FBuryFan12%2FBC24C383-0017-431E-89F4-B8746EB8A28B_zps6kfdiw7a.jpg&hash=ab320f41efa96afe85ff6772fcb6bab312a9159d)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fq739%2FBuryFan12%2F087FC5BE-AE4C-4E34-AC35-6E4D7DB75FF9_zpsnjqvpo91.jpg&hash=cd91c3dc775447acfdb81d3424756156aa79a58a)
Post by: lincolnshirepoacher on August 27, 2016, 11:26:47 am
Post by: ChrisGT on August 27, 2016, 02:46:19 pm
Here was the EGR valve on my 2007 63k BMN engine. :sick:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fs104%2Fbailachris%2FIMG_2012.jpg&hash=a1d3adb5b0f3541b3b83526680091abcd176bb1e)
And then after a good clean:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fs104%2Fbailachris%2FIMG_2023.jpg&hash=adbe32cf940a58584fa595b4a0e3a10d31720fb3)
Here's some of the crap that came out of it:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fs104%2Fbailachris%2FIMG_2025.jpg&hash=94f7fcf243b09059758211e973f5066d2b9103ad)
Definitely running a lot smoother and idle is much better (was quite lumpy ever since getting the car a few months ago)
Chris
Post by: lincolnshirepoacher on September 01, 2016, 08:32:58 am
On another note does my 54 plate have a dpf filter??? As been seeing mixed threads.
Post by: jason_rmh on September 01, 2016, 09:07:58 am
What engine is your car? BKD (140) or BMN (170)?
I don't think BKD engines came with DPF.
Glad the guide helped.
Jas
Post by: lincolnshirepoacher on September 01, 2016, 10:24:08 pm
Post by: jason_rmh on September 01, 2016, 10:42:02 pm
I'll check the fault code in vcds.
If you can do the same, and compare to mine it will help narrow it down.
Post by: Llew on September 21, 2016, 11:43:58 am
Post by: jason_rmh on September 21, 2016, 12:48:50 pm
Post by: Llew on September 21, 2016, 03:46:28 pm
Post by: jason_rmh on September 21, 2016, 03:49:23 pm
Post by: Llew on September 23, 2016, 10:16:40 am
Post by: Llew on September 30, 2016, 03:18:09 pm
Post by: hannybal on March 19, 2017, 07:34:44 pm
how was the car after egr removal but without mapping out? limp mode, something? major things. im driving 60miles per day. i need to know if i wil be able to go to work safely til egr mapping out.
Post by: Llew on March 20, 2017, 04:28:27 pm
Post by: jason_rmh on March 20, 2017, 04:42:21 pm
You will get the error light on instrument cluster but the car will drive fine.
Jas
Post by: TDIQuattro on June 16, 2017, 05:29:30 pm
You can drive safely until egr is mapped out.
You will get the error light on instrument cluster but the car will drive fine.
Jas
Nice one for producing this guide, I want to do it but I don't have the tools required and fear I'll mess something up. I noticed you are in Preston? I'm also located there too, if I were to pay you do you reckon you'd be able to do it for me?
Cheers.
Post by: jason_rmh on June 17, 2017, 10:39:18 am
Nice one for producing this guide, I want to do it but I don't have the tools required and fear I'll mess something up. I noticed you are in Preston? I'm also located there too, if I were to pay you do you reckon you'd be able to do it for me?
Cheers.
Hi,
I could do it for you.
Do you want the cooler removing too?
Are you getting an egr delete kit from dark side?
What engine do you have?
I may not be able to do it for a few weeks though.
Jas
Post by: TDIQuattro on June 17, 2017, 07:22:56 pm
Nice one for producing this guide, I want to do it but I don't have the tools required and fear I'll mess something up. I noticed you are in Preston? I'm also located there too, if I were to pay you do you reckon you'd be able to do it for me?
Cheers.
Hi,
I could do it for you.
Do you want the cooler removing too?
Are you getting an egr delete kit from dark side?
What engine do you have?
I may not be able to do it for a few weeks though.
Jas
Hi Buddy, It's not a darkside kit but its very similar (https://scontent.xx.fbcdn.net/v/t34.0-12/19046559_10154940794253026_2142887233_n.jpg?oh=39726e1eb5e0277899f126d0e8f174da&oe=59484A0B) yeah ideally if you could delete the cooler aswell that would be grand. It's a BMN engine. Yeah thats fine bud - just let me know when your free and how much you want and I can bring it down :happy2:
Post by: R88TWE on July 31, 2017, 05:27:48 pm
Absolutely awesome guide! ...Only trouble is I can't see a single photo thanks to Photobucket!
Any chance you could email the pdf as the drive link isn't working? That would be brilliant if you could
Cheers,
Rob
Post by: jason_rmh on August 07, 2017, 06:03:06 pm
Thanks Jas,Sorry for delay!
Absolutely awesome guide! ...Only trouble is I can't see a single photo thanks to Photobucket!
Any chance you could email the pdf as the drive link isn't working? That would be brilliant if you could
Cheers,
Rob
I've updated the pdf link on the initial post.
I'll move the pics to a different hosting items when I get chance.
In the mean time, I think there is a Google chrome extension you can install that makes the photobucket images work, but that won't work on your phone I don't think.
Jas
Post by: v4rley on September 09, 2017, 11:56:09 am
Try out do the delete but seem to have different pipe routing
http://www.oemepc.com/vw/part_single/catalog/vw/markt/RDW/modell/TOU/year/2005/drive_standart/409/hg_ug/121/subcategory/121045/part_id/3691348/lang/e
Post by: jason_rmh on September 11, 2017, 10:31:15 pm
Post by: v4rley on September 11, 2017, 10:36:13 pm
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fi65.tinypic.com%2F25gazpi.png&hash=47dba854071d73d7d0dd0edb2fa02ee7caa64e3e)
Your guide pipe A which is 34 on the diagram goes to the bulk head which you remove and disregard but mine as the diagram goes around to the front of the engine
Post by: jason_rmh on September 12, 2017, 09:06:32 am
There are two pipes into / from the bulkhead, these feed / return the heater matrix and join it to the rest of the coolant system, including egr valve and oil cooler.
On mine, the hose from bulkhead went straight to the egr cooler.
There was another pipe from the cooler back to the engine.
The hose TO egr cooler from bulkhead was removed / discarded.
The hose FROM cooler to engine was attached to new coupler to allow it to attach to the bulkhead, completing the coolant circuit, basically bridging the gap left by the cooler.
On yours, the circuit should be the same, you need to identify the hoses to be bridged, left by the cooler.
I'll have a close look at mine this afternoon to refresh my mind!
Jas
Post by: v4rley on September 12, 2017, 12:34:42 pm
Your guide is perfect just my pipework and the diagram seems to route differently
Post by: jason_rmh on September 12, 2017, 07:50:24 pm
It looks like the 2003 model. Is your Touran 2003?
My golf is 2006, i didn't realise there was a difference, until now! :scared:
Here is 2003 BKD(as you posted):
(https://farm5.staticflickr.com/4377/36793915810_ec3a64bcfd_c.jpg)
Here is 2006 BKD:
(https://farm5.staticflickr.com/4413/36793915770_cf81d141cd_c.jpg)
So, on 2006:
Hose 45 (from bulkhead to cooler) was discarded.
Hose 44 (from cooler to engine) was connected to the new coupler and then attached to the bulkhead where 45 originally connected to.
On 2003, the egr cooler does not connect to the bulkhead.
It connects at a different point on the cooling system.
So, following the same method, you should:
On 2003:
Hose 34 (from engine to cooler), discard.
Hose 32 (from cooler to engine), connect to hose 48.
You probably wont need the coupler.
You may even be able to connect 32 to 37. As long as it closes the loop and the connection is secure, you will be good to go.
Does that make sense? The main thing is to look at the hoses and find a suitable way to connect them.
Jas
Post by: v4rley on September 12, 2017, 08:16:45 pm
How intriguing, I had search and search and could find the later setup on diagrams didn't think to look for later models. Mine is an 05, not sure why the revision was made, maybe to product a quick heating system for the cabin?
I had some advice from fb over the weekend regarding solution but still though I was probably missing something and wanted it documented for future reference. I and going to look at joining 32 / 34 as one won't reach alone. Initial solution is a bit of 22mm copper as that's what I had to hand.
Thanks, every days a school day :laugh:
*on further investigation it looks like it might be a touran thing
Post by: jason_rmh on September 12, 2017, 08:38:26 pm
You could use some black 20mm conduit with some jubillee clips.
Or a more permanent solution would be some silicon hose of the correct internal diameter and wall thickness to bridge the gap from 25 to 37, both are solid so silicon hose with jubillee clips would work well.
Jas
Post by: omn on February 13, 2019, 03:02:58 am
After many many hours on youtube and general searching, I found this amazing tutorial, so, first of all, thank you.
I've an Audi A3, 8p, LHD, Diesel, 140hp, BKD engine, from September 2005. It has a DSG gearbox.
Recently I got this error which put me back on this EGR issue. EGR was cleaned up less than a year ago so I think it's probably gone. Instead of replacing it, I'm into the idea of deleting it!
Error:
16785 - EGR System
P0401 - 000 - Insufficient Flow - Intermittent
My main question is: Is there any problem reproducing your tutorial for a car with DSG automatic gearbox?
Thank you for your time and work.
This is a GREAT guide!
Regards
Post by: Andy on February 13, 2019, 12:59:08 pm
Post by: alex4y on April 19, 2019, 02:10:02 pm
I have the BMN engine and thinking of deleting my EGR cooler as there is a coolant leak behind the engine and I suspect the EGR cooler. I have my EGR valve mapped out, so don't need the cooler anyway. Funny thing is that the slow coolant leak started after the DPF delete and EGR disable.
My question is: how do I get to the EGR cooler? since it is under the turbo and difficult to get to? I was thinking of lifting the car up (I have access to a workshop with proper lifts) and work underneath, taking one of the driveshafts off?
And also, since the cooling system on the BMN engine is slightly different, how do I close the cooling system circuit?
There is an image with the cooling system, with 65 being the EGR cooler:
Any help will be appreciated. Thanks.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.oemepc.com%2Ffiles%2Fimg%2FBilder%2F474%2F474121520.png&hash=7cad55c5265d5f6f2bc3a1d4afc3e052794d24af)
Post by: AJPowell on April 20, 2019, 05:22:14 pm
Post by: muff1991 on April 25, 2019, 10:33:33 am
Hi guys,
I have the BMN engine and thinking of deleting my EGR cooler as there is a coolant leak behind the engine and I suspect the EGR cooler. I have my EGR valve mapped out, so don't need the cooler anyway. Funny thing is that the slow coolant leak started after the DPF delete and EGR disable.
My question is: how do I get to the EGR cooler? since it is under the turbo and difficult to get to? I was thinking of lifting the car up (I have access to a workshop with proper lifts) and work underneath, taking one of the driveshafts off?
And also, since the cooling system on the BMN engine is slightly different, how do I close the cooling system circuit?
There is an image with the cooling system, with 65 being the EGR cooler:
Any help will be appreciated. Thanks.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.oemepc.com%2Ffiles%2Fimg%2FBilder%2F474%2F474121520.png&hash=7cad55c5265d5f6f2bc3a1d4afc3e052794d24af)
hi mate,
I have the BMN engine in my touran and done the EGR & Cooler delete (but I left the cooler on the engine as couldn't be bothered to remove it - so I advise just to leave it lol) the pipe you need to route is "37" this needs to be disconnected from the cooler and then bent/flexed up to fix onto number "44" coupler which is the Top pipe coming from the bulk head (heater matrix). I believe you have to get a new straight coupler too. the coolant diagram is a pig to make sense of if you ask me, but basically in my own a$$ about face words.. if you go to the right hand side of your engine under the air intake pipe, you'll see the coolant hose coming from the radiator, it goes to the connector block "60" follow it along going towards the back of the engine and you'll see the rubber hose leave the block "60" it instanty ducks and dives under the metal boost pipe. you'll need to follow that and then disconnect it from the cooler and then connect it to the "top" heater matrix pipe. Be careful not to kink it as you don't want to restrict much flow for the coolant. So disconnect hose "43" from "44" coupler and pipe, then connect hose "37" to "44" coupler pipe. I hope this makes sense. I did mine a few years ago and still ok, apart from clip on intake pipe decided to eat a pin prick hole into the hose - silly me should of turned the squeeze points of the clip around so it didn't touch the hose lol shame I didn't see this when doing the job. but its all done and been fine ever since. by doing this, the EGR cooler is then completely bypassed so "closed circuit" again.
Post by: alex4y on May 04, 2019, 12:52:46 pm
Hi guys,
I have the BMN engine and thinking of deleting my EGR cooler as there is a coolant leak behind the engine and I suspect the EGR cooler. I have my EGR valve mapped out, so don't need the cooler anyway. Funny thing is that the slow coolant leak started after the DPF delete and EGR disable.
My question is: how do I get to the EGR cooler? since it is under the turbo and difficult to get to? I was thinking of lifting the car up (I have access to a workshop with proper lifts) and work underneath, taking one of the driveshafts off?
And also, since the cooling system on the BMN engine is slightly different, how do I close the cooling system circuit?
There is an image with the cooling system, with 65 being the EGR cooler:
Any help will be appreciated. Thanks.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.oemepc.com%2Ffiles%2Fimg%2FBilder%2F474%2F474121520.png&hash=7cad55c5265d5f6f2bc3a1d4afc3e052794d24af)
hi mate,
I have the BMN engine in my touran and done the EGR & Cooler delete (but I left the cooler on the engine as couldn't be bothered to remove it - so I advise just to leave it lol) the pipe you need to route is "37" this needs to be disconnected from the cooler and then bent/flexed up to fix onto number "44" coupler which is the Top pipe coming from the bulk head (heater matrix). I believe you have to get a new straight coupler too. the coolant diagram is a pig to make sense of if you ask me, but basically in my own a$$ about face words.. if you go to the right hand side of your engine under the air intake pipe, you'll see the coolant hose coming from the radiator, it goes to the connector block "60" follow it along going towards the back of the engine and you'll see the rubber hose leave the block "60" it instanty ducks and dives under the metal boost pipe. you'll need to follow that and then disconnect it from the cooler and then connect it to the "top" heater matrix pipe. Be careful not to kink it as you don't want to restrict much flow for the coolant. So disconnect hose "43" from "44" coupler and pipe, then connect hose "37" to "44" coupler pipe. I hope this makes sense. I did mine a few years ago and still ok, apart from clip on intake pipe decided to eat a pin prick hole into the hose - silly me should of turned the squeeze points of the clip around so it didn't touch the hose lol shame I didn't see this when doing the job. but its all done and been fine ever since. by doing this, the EGR cooler is then completely bypassed so "closed circuit" again.
Many thanks for the guidelines mate! I lifted the car up again, and traced the hose (40) to find out it goes straight into the bulk head, as you said. I got the straight connector, and will be doing it maybe next week. I wanted to completely remove the cooler (i got blanking plates for that) but might leave it there like you said as it is difficult to get to. Hopefully pipe 37 is ok, as I can't exactly see where it's leaking from. It is very slow leak, I can see drips in that area, and smell the coolant when engine is hot.
Once again thanks.
Post by: muff1991 on May 07, 2019, 11:31:59 am
Post by: Steve192vw on May 23, 2020, 11:47:46 am
Post by: kevster996 on October 13, 2020, 05:14:05 pm
Everythings been checked out, turbo off and cleaned, tested, vaccuums checked, new MAF (bosch), new actuator.
Im thinking it must be the remap thats not happy with no EGR now?
Post by: M4rkyj on December 04, 2020, 05:13:35 pm
Ive just signed up and this is my first post here, purely to say a massive thanks to Jas for an amazing write up.
Followed it as much as I could, and managed to get the egr off and the dark side blank pipe fitted, removed the egr gas pipe, ended up hacksawing it because of the turbo oil pipe and the coolant return from heater matrix that are in the way, and also deleted the cooler, however left it in situ, as it is a PITA to remove, so just bypassed for now.
First start up seems like she’s a lot smoother and ALOT less smoke coming from the pipes. I have noticed it idles at a higher RPM about 1100 whereas before it was about 8/900rpm.
I’ve got a mk5 golf 170 BMN engine and it’s had the DPF delete and remap to go with it. Ever since then the idle has been horrible and plumes of acrid smoke from the exhaust. Hopefully the egr delete has made it easier to breath and also think the dpf map included the egr delete as it’s not thrown up any lights.
Thanks again Jas, legendary write up and I’m sure it’s helped more than just the people who have commented 👍🏼👍🏼