The 1.9L PD TDI powerquest

**gldgti** · 08-01-2013, 10:13 AM

Just dive in greg, its easy.

I bought my timing belt tool set from a UK ebay store...eBay Australia: Buy new & used fashion, electronics & home d

myturbodiesel.com has a good few writeups:
Mk5 VW Jetta TDI DIY and VW TDI forum

**gldgti** · 11-01-2013, 04:38 PM

So here it is - the gldgti egr/asv delete pipe - manufactured from 304 SS:

Keen observers will note the lack of an o-ring groove - well, thats because its way too hard and too expensive for me to get one machined. However, its very cheap and easy (and just as effective!) for me to cut a paper gasket with a hobby knife and use that instead (this is what I did on the last race pipe I made - for the PD150 intake I put on my old mk3 golf).

If any of you keen dieselers would like one of my race pipes, I will also supply you with a gasket because I'm such a nice guy

**gldgti** · 13-01-2013, 05:07 PM

MISTAKE!

I must have accidentally scaled my drawing for the flange a bit, unfortunately my lovely pipe doesnt bolt up. All the holes are about 1mm closer to eachother than they ought to be.

Ahh well, revised edition coming soon

I think this time I will open up the ID to 57mm and make a reducer from 63.5mm to 57mm for the pipe for easy fitting of 2.5" boost piping rather than 2".

Anyway it gave me a chance to clean out my ASV and egr valves, which I did. They were pretty dirty but not as bad as I expected. Also, the nature of the soot buildup in the manifold is very dry - I put this down to me having a provent fitted for the past 40,000km.

**gldgti** · 14-01-2013, 10:01 AM

Another thing I did yesterday, which seems to work perfectly:

To defeat the EGR on the 1.9TDI, it is sufficient to simply unplug the vacuum hose from the egr valve and block it. Thats it.

I thought it might throw the CEL or something, but no, drove the 50km to work this morning with no problem.

So, forget your blanking plates. You dont even need to lift a spanner. Just disconnect the vaccuum pipe, block it and cable tie the hose out if the way (or buy a vacuum plug and block the outlet on the big actuator matrix instead.)

With vacuum disconnected, the valve will just remain closed and no exhaust will be recirculated.

***EDIT*** after another few km, the CEL popped on with the 'emissions workshop' notification on the dash. Oh well, I guess I jumped the gun on this one too!

Otherwise the engine runs just fine though.

**gldgti** · 18-05-2013, 10:16 PM

busy day today...

took the car to work, back end on ramps and front on stands just so I could squeeze under and undo the downpipe etc....

I didnt take any during photo's unfortunately, I was a bit flat out - but finally:

and a bit of noise:
Skoda Octavia 1.9tdi 2.5" stainless exhaust - YouTube

So - apart from the coming off boost whistle, its remarkably quiet still with only that muffler, but by golly has it gained some top end - Fantastic!

**Greg Roles** · 19-05-2013, 08:33 AM

Nice work Mr Stainless Steel, awesome to see someone actually fabricating rather than just buying off the shelf. So much more rewarding, when you get the scale correct anyway! : )

**gldgti** · 19-05-2013, 11:12 AM

Originally Posted by Greg Roles

Nice work Mr Stainless Steel, awesome to see someone actually fabricating rather than just buying off the shelf. So much more rewarding, when you get the scale correct anyway! : )

Ineed - its nice when things fit! Thanks Greg.

This is my 3rd exhaust system, and I think now i've got it down pat. Noteable features in this system are each flange joint has one flange floating so that you can align the two pipes perfectly at the joint. This job ended up being more complicated than the one I did on the cabriolet, but it took about an hour less fab time just because I had to do a lot less checking - and it fits better.

I almost did a de-cat, but finally decided just to see how it does. One good thing is that the stock downpipe has a 2.5" inlet anyway, and after the cat is a 2.5" ID flex joint - only after that does the stock system reduce down to 2.25". So, The whole system is still 2.5", and legal to boot.

**Jarred** · 19-05-2013, 12:00 PM

Is it just me or does the standard exhaust look pretty decent interms of bend quality?

How does it go (sound) without the resonator in there?

**gldgti** · 19-05-2013, 06:52 PM

Originally Posted by Jarred

Is it just me or does the standard exhaust look pretty decent interms of bend quality?

How does it go (sound) without the resonator in there?

I agree the standard exhaust is very good really. The press bends are only marginally 'squashed' compared to the normal pipe diameter. When I'd got under there first, I considered not doing the job at all given that I only went up to 2.5".

But, its a 35% increase in cross sectional area (not including the squashes in the bends, so effectively more) and the new exhaust is lighter and straighter.

TBH the sound is almost no different. You can tell its slightly deeper, you mainly notice this when you start it and turn it off. It also lets more of the turbo noise through, not whine but the whoosh and flutter you get with VNT's. But again, its not all that noticable.

I would say unless you were told it wasnt stock you would think it still was.

It goes a lot better, above 3000 rpm - hugely noticable increase in power up there. Where it used to really fall off at around 3500, now it keeps pulling until around 4000. Understandably I cant really notice any difference under 2500 rpm. I have noticed boost spiking to 1.5bar more easily though.