how to fit a egr delete pipe

[transporterq]

Evening,

My EGR delete pipe from Darkside today, my wife ask what it was after the delivery guy left, I said EGR delete. Wife turns round and says to herself as she walks away, no idea what he just said, wished I had not asked! What did I say, she asked, I told?
Anyway here’s my problem, no instructions in the kit, some of it looks straight forward, but some small headless bolts and not sure about the coolant side of things.
Can find no information on line, expect for a 1.9 diesel on a B5 Passat, so does any one know how to correctly fit these things, to a B6, 103 kW diesel motor, photos or diagrams would be a great help, please?

Peter.

[getjet]

The egr delete is straight forward. Just remove the asv/ egr valve and replace.

I think you may also be talking about a cooler delete also? I have nfi but looks like a PITA.

[Greg Roles]

Darkside are on holidays right now too....but Allards in the UK and Dieselgeek in the USA both sell the same thing, perhaps they have relevant instructions???

[transporterq]

Received an answer yesterday, "The small grub screw is to blank the hole at the back. The long one has a hole in it, this is used if you have a boost gauge and goes in the small hole instead of the small grub screw." Just waiting for some warmer weather before I fit the pipe and a few other parts I have brought.

[getjet]

You do realise that this will throw a CEL and you'll need to get it tuned out?

What other parts do you have to go in/on?

Not sure if it will help but here is a rough guide...

Once you have the right spline sockets (if thats what they're called?) its straight forward.

Disconnect battery (always a good idea...)
Remove vaccuum connector to EGR valve (small rubber pipe on the left that just pulls off)
Undo and remove the 2 EGR pipe bolts (silver pipe from the rear of the engine to the EGR valve)
Take off clip and remove the intercooler pipe from bottom of ASV.
Remove 3 bolts holding the ASV.
Remove EGR.
Clean and let dry.
All of above in reverse.

You don't even need any gaskets or anything. Just be careful with the rubber ones.
The only other thing to be aware of is that one of the bolts holding the ASV on also holds the EGR valve on. IE: it goes through both. Bloody confused the **** out of me when i was doing it... thought id lost a bolt or a previous mechanic did a dodgy

[jazd]

Pic here -
http://www.vwwatercooled.org.au/foru...tml#post825677
I also mention the long bolt

Is your kit EGR only or ASV as well?

You need to block off the EGR pipe with the blanking plate that they supply.

[getjet]

Are you leaving the cooler or do you plan on getting rid of it? I suppose for you pd170 guys, it's below the turbo instead of on top.. Probably make some room with it removed though. Reckon' thers any dramas with it being blocked at the egr pipe rather than manifold?

[transporterq]

"You do realise that this will throw a CEL and you'll need to get it tuned out?"

Yes know it will create an error code, planning on replacing the cat as well to complete the exhaust system, have a S/S 3" from after the cat back, that I believe will also create an error code, so I was going to get it all done and then have the codes cleared.

"Are you leaving the cooler or do you plan on getting rid of it?"

Leaving the cooler on.

"Is your kit EGR only or ASV as well?"

I have just an EGR delete kit.

"What other parts do you have to go in/on?"

Have already fit an APR air filter, my father, a retired tool maker has made some brackets up for me to hold it in place, allot of movement in it, just bolts at the front an not much else holding it. Also have an oil catch can to fit, not sure if the hose size is correct, seems a bit small and I do not want to starve the motor as I have since on some YouTube clips of others fitting them on their VW's.