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EGR delete and intake manifold clean

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Yardie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rebuild Quote  Post ReplyReply Direct Link To This Post Topic: EGR delete and intake manifold clean
    Posted: 26 Apr 12 at 07:26
thread dredge
At 126K km(79K miles)
Made an EGR blanking plate and gasket and fitted recently
Cleaned the Anti Shudder intake pipe and approx 150mm of the intake manifold of black gooey sludge.
Engine seems maybe a little more responsive down low,but hard to tell
Going to do the full intake eventually
Did notice a little oil residue in the Intercooler to Intake Manifold rubber hose too 
 


Edited by Rebuild - 26 Apr 12 at 07:29
Steve
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Happy Yellow Quote  Post ReplyReply Direct Link To This Post Posted: 14 Sep 10 at 12:47
 
I blanked my EGR system, and thought that it was saving fuel.  I could not be 100% sure until I gave it a proper test.  Now I have.
 
Every so often I drive from Riga, Latvia to Bergerac, France.  It's 2900 km door-to-door.  I compared this year's fuel consumption figures with last year's (also in August):
 
2009 Day 1:  8.9  (89 km/h)
2010 Day 1:  7.5  (87 km/h)
 
2009 Day 2:  8.9 (104 km/h)
2010 Day 2:  7.8 (100 km/h)
 
2009 Day 3:  9.3 (85 km/h)
2010 Day 3:  8.2 (81 km/h)
 
2009 average: 9.0 (92.6 km/h)      in English: 31.39 mpg (57.54 mph)
 
2010 average: 7.8 (89.3 km/h)      in English: 36.48 mpg (55.49 mph)
 
 
 
Yes, my average speed was down a little, and I can confirm that I drove for 55 minutes longer in 2010 than I did in 2009 (30:50 v 31:45), but that slower average cannot account for all that saved fuel.  Can it?  I saved about 13%  or 36 litres  or  €40!  That's 3 reasonable French meals!
 
Note:  I've quoted fuel consumption in litres per 100 km as that's how my vehicle works; how I think, and it's esier once you get your head around it.
 
I've treated each day as equal so as to make calculation more simple.  In fact:
 
Day 1: 1060 km   Soviet Union: quiet roads with low speed limits and too many police.
Day 2: 1003 km   Germany: all Autobhan.
Day 3: 800 km     France: N roads only, no Autoroute.
 
Actual total: 2863 km
 
Also, it's nice only having to fill-up 3 times rather than 4.
 
 


Edited by Happy Yellow - 14 Sep 10 at 12:59
2005 Sari Yellow Caravelle 174/AXE 200k miles
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Post Options Post Options   Thanks (0) Thanks(0)   Quote aledw Quote  Post ReplyReply Direct Link To This Post Posted: 03 Aug 10 at 14:59
Just fitted an EGR blanking plate which I bought from Brickwerks's ebay site. My 120K 174 AXE now drives noticably smoother in first and second gear at low revs. Big smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lwb174caravelle Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 16:42
Originally posted by mistadave mistadave wrote:

some insurance companies only want to quote for bog standard cars, you have to insure with a company that specialises in modified cars. Most of them will realise that a properly modified car will be the pride and joy of the owner and so they are likely to look after it, less likely to have an accident. Where as the big mainstream companies will just instantly see you as a boy racer and so refuse to insure you, or do so at great cost.

Looks like I will have to use a different insurance company if I want to declare a blank, a de-cat, or an Allard pipe. It's a shame because they gave me a damn good price this year, beating the next nearest company by over £100 and they included all the optional insurance extras.Unhappy
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mistadave Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 16:29
some insurance companies only want to quote for bog standard cars, you have to insure with a company that specialises in modified cars. Most of them will realise that a properly modified car will be the pride and joy of the owner and so they are likely to look after it, less likely to have an accident. Where as the big mainstream companies will just instantly see you as a boy racer and so refuse to insure you, or do so at great cost.
55 reg 174 LWB raven blue camper. Celtic remap, pipercross filter, MIJ de-cat and exhaust, Forge intercooler, Allard EGR powerpipe and oil catch tank
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lwb174caravelle Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 15:14
Hmmm. Confused

My insurance company (a well known one) says:
We will not be able to provide cover if your car has been modified to increase the top speed or acceleration.

Another big company (Swinton) defines modification as:
A vehicle which has been altered in a way that affects its appearance or performance.

This is starting to look tricky!




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Post Options Post Options   Thanks (0) Thanks(0)   Quote mistadave Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 13:27
When i did my insurance with just kampers/adrian flux I listed most of the major modifications, they didn't seem interested in what the modification entailed, it was more about the value of those modifications should i need to claim. I must admit the remap isn't on there yet, but i tested the water with the wheels, lowering, exhaust, decat, body modifications. I was amazed it made hardly any difference, still loads cheaper than insuring it as a normal van with direct line, who also wanted the earth of any modifications.
55 reg 174 LWB raven blue camper. Celtic remap, pipercross filter, MIJ de-cat and exhaust, Forge intercooler, Allard EGR powerpipe and oil catch tank
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lwb174caravelle Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 11:11
Originally posted by SteetonMVP SteetonMVP wrote:

Has anyone considered the insurance issues.  Have we all answered the question by the insurance company "Has the vechicle be modified in any way?"

Good point! I guess the EGR blanking plate would be pretty difficult to spot when looking at the engine, however a nice chrome bypass pipe or cat-less exhaust would be spotted more easily. 

Are we modifying or improving? If we put better quality tyres, wipers, filters, exhausts etc than the fitted OEM ones is that a modification? 

It would be good to have a post on this topic from someone who has first hand knowledge of the insurance implications. Do we declare or keep quiet?

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Post Options Post Options   Thanks (0) Thanks(0)   Quote SteetonMVP Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 10 at 01:08
Has anyone considered the insurance issues.  Have we all answered the question by the insurance company "Has the vechicle be modified in any way?"
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Post Options Post Options   Thanks (0) Thanks(0)   Quote blackvanman Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 10 at 13:50
need the codes for stuff, can't see it on ross tech site, cleared svc reminder tho after changing oil n filters. i thought my van was can but apparently not
'09' 174 kombi, swb, pearl black
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Happy Yellow Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 10 at 12:06
Originally posted by mistadave mistadave wrote:

egr wont cause sludge in the intercooler as it enters after the intercooler. The intercooler will just have some oil in it from the crankcase but it shouldnt restrict it too much.

I was talking to the guys at allard and the later "electronic" egr actually has a water cooler as well, to try and cool the gasses before they are added back to the manifold.
 
Yes, you're quite right about about the soot not getting to the intercooler - I realised I was wrong last night after I'd written it. Embarrassed
 
I noted on Elsawin that the 2005 auto version had a liquid cooled ERG duct while my manual 2005 AXE has no cooling. 
2005 Sari Yellow Caravelle 174/AXE 200k miles
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mistadave Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 10 at 09:25
Good question, unfortunately i think it will require a remap of some kind, but i would suggest asking pendle performance. The engine will still try to regenerate and without the innards there the extra diesel it sends to burn on the dpf would just go out the exhaust - probably not a great idea. Also it would probably detect that it isn't getting hot enough so it would try to regenerate more often and with more fuel, so you would just end up sending loads of fuel out your exhaust pipe!

Remember that you will only void your warranty if the part failure can be attributed to whatever you have modified. I.e if you remap your engine, and they happen to find out, you will still be covered if you wipers stop working. I wold think that the VW guys would actually be quite grateful if you got rid of the DPF, they are probably a bit tired of seeing them! I don' think they could attribute the failure of any other part to the removal of the dpf either, since all it normally does is cause problems. The same goes for the EGR

To be on the really safe side, get one of the switch able boxes that many of the tuners do - not one of the crap plug in and go ones, but one like celtics e-motion. one map stored on there is your standard map, just modified to turn off the dpf stuff, the other is a proper remap. just stick on the normal one if you take it in, and enjoy the other one the rest of the time!

I'd be lying if i said there wasn't a risk in all this, but you taking out one of the biggest problem bits of kit in the van, so that's a load of risk gone. The chances of something else like a turbo going are in reality pretty slim, then the chanced of vw discovering that you are remapped and not covering it are slimmer again.

With our new car im just looking at it like this: I'm spending a lot of money to get a high spec new car so that i can choose exactly what it is like, and i can own it from new so that i know it has never been mistreated. Most of the stuff is still covered under a warranty, and if something goes that isn't it is a relatively small price in relation to the whole car, a small price to pay for enjoying the full potential, and economy of the car.

Just think, if there was the 180 T5 available from VW, and then the 240bhp uber version with dpf removed, better economy etc in the showroom, how much extra would you be willing to pay for that version? Probably a lot more than the cost of the dpf and remap, and that extra is the amount you "put to one side" in case the worst should happen!
55 reg 174 LWB raven blue camper. Celtic remap, pipercross filter, MIJ de-cat and exhaust, Forge intercooler, Allard EGR powerpipe and oil catch tank
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Billy-jim Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 10 at 08:20
Hi mistadave, you have advised me on this subject before.

Im picking up my new van todayBig smile.

Im all in favour of the dpf delete and egr blank but am very wary of voiding the warranty in case i run into problems with it.

 Do you have an opinion on weather you could hollow out the dpf with no ecu changes .I mean sensors can detect when the dpf is blocked ,I imagine because of a pressure build up ??? , but if all the gasses pass through would the ecu presume all is ok and not go into regeneration mode!!!

sorry if its a silly question
B-J

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Post Options Post Options   Thanks (0) Thanks(0)   Quote mistadave Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 23:07
egr wont cause sludge in the intercooler as it enters after the intercooler. The intercooler will just have some oil in it from the crankcase but it shouldnt restrict it too much.

I was talking to the guys at allard and the later "electronic" egr actually has a water cooler as well, to try and cool the gasses before they are added back to the manifold. Id block it and get a remap to turn off the warnings, regardless of warranty. As soon as we get our new a3 its having the dpf hollowed out, egr blocked and remap. If you have spent that much on a car or van, why would you leave it choked, besides, the cost of a dpf replacement, which isn't covered under warranty anyway, is about £600, then start adding the fuel you save by not having an egr or dpf. you could just save it in a pot in case you have something fail on the engine that isn't covered because of the modifications, and enjoy the added performance.
55 reg 174 LWB raven blue camper. Celtic remap, pipercross filter, MIJ de-cat and exhaust, Forge intercooler, Allard EGR powerpipe and oil catch tank
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Post Options Post Options   Thanks (0) Thanks(0)   Quote energysolutions Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 22:13
Originally posted by blackvanman blackvanman wrote:

well i do have vcds now!!
 
Yes indeed.....Wink
 
How you getting on with it?
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote blackvanman Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 20:43
well i do have vcds now!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote energysolutions Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 18:16
I`d be more concerned about the fact that your van is a later model and they usually throw up an error code when the blanking plate is fitted which has two consequences:
 
1) A light on the dash (annoying)
2) A stored fault code in the ECU which the dealer can find/question if the ECU is interogated during a service (unless of course you clear the code with VCDS before the serviceWink)
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lwb174caravelle Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 16:00
It's an easy fit and likewise it's easy to remove so if you thought you might have a warranty issue I would remove it before taking it into the stealers.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote blackvanman Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 15:53
Do u think i will have warranty issues if i fit an egr blanking plate? it sounds like a premium mod!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote lwb174caravelle Quote  Post ReplyReply Direct Link To This Post Posted: 29 Jul 10 at 13:57
Happy Yellow. 120 miles at 42-56 mph !!! That must be soul destroying Confused    
And here's me thinking 10 miles of roadworks with 50mph average speed cameras is torture ! But having said that, I would love to get 47mpg. 

It will be interesting to see what a steady 50 will return with my new blacking plate fitted.

Just also took my little plastic restrictor plate off . I will see if I can notice any difference later today.
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