Let the tinkering begin...

[Greg Roles]

OK back to the tinkering!

I did another read of the 125kw tech bulletin, and noticed that if the EGR throttle flap and valve units lose voltage, they just go to default positions.
The throttle flap goes to full open, and thus doesn't restrict incoming air. I liked the sound of that! The EGR inlet valve at the same point simply stays shut, and you get no exhaust gas recycled. Again, sounds good to me, performance wise. I realise it will raise the NO emissions, and exhaust temps a bit, but I figure if you decided to ditch the EGR in this manner, a chip would make the car run more efficiently, and the net increase in emissions would probably be minor ( happy hippies? )

Seriously, I'm after power, but not at the expense of the lower emission footprint I am now driving!

So I unplugged them both, and drove to work.

First up, you get the error codes, and the flashing glow plug and engine light. Easy to ignore, how much better did it run?

It drove like the winter button was on. Not AS lethargic, bit a noticable drop in performance. I figured the flap somehow works in with the fuel map at lower revs, and perhaps it was now running lean, as perhaps this flap does indeed act more like a petrol throttle. Weird. Anyhow, I pulled over and plugged the throttle flap back in, and she was back to normal. I'm leaving the EGR valve unplugged for now to see what happens. Theoretically I'm now getting a better charge with no exhaust included, and hopefully more stick. EGR's will go up, but I can't see why it would be any more than a chipped car. I need to find an XR6 or S pack to race. EDIT, the EGR flap defaults to not running the cooler, but hot, uncooled exhaust still passes. The flap just lets hot exhaust enter till the water temp goes over 35 degrees, then it switches over so the exhaust goes through the cooler. This aids warmup.

What WAS interesting is that with both unplugged the car had a much more diesel like vibration on shutdown. Still as quick to stop, but a noticable rattle and vibration. I know the throttle flap shuts off at shutdown to stop any run-on. BUT when I plugged the flap back in, and stopped just now, it's still the same!

Weird!

Wonder what else you can unplug......

[Greg Roles]

OK I ended up plugging them both back in and erasing the error codes with the trusty VAG-com cable. With just the EGR valve disconnected, on boost was the same, but off boost response was down. It seemed to take longer to get to the 2000rpm fun range, and really seemed to make the car "on-off" power. I;m going to have to contemplate that, but perhaps with no exhaust gas included, now the car is running rich off boost? EDIT: As there was no cooling of the exhaust gas, I was just adding full temp exhaust.

Perhaps when the engine throws an error it drops the power, or perhaps the engine map is just really tied in to the EGR circuit and exhaust included in combustion. Hmmmmmmm.

Anything that adds heat to the charge air post intercooling has to be hobbled in my opinion!

[Jaymz]

Who knows, but i can say this, if you f**k it then we'll all know what not to unplug!

[Greg Roles]

Definately ran MUCH better with the error code removed. Even plugging everything back in, it still seemd to run as if the vanes weren't really working down low with the error light on.

C'mon you big girls, man up and start unplugging stuff!

[Greg Roles]

Yipee! Scored this for $327 delivered from Germany!



seller was 1000autoteile. I had to use babelfish to communicate, which was a challenge, but it worked out!

[Logzy]

Yipee! Scored this for $327 delivered from Germany!



seller was 1000autoteile. I had to use babelfish to communicate, which was a challenge, but it worked out!

Nice one.
LOL, i had to do the bablefish translate too when i got my vw bluetooth.
It did the job, just takes a little longer writing and reading the emails.
Was that seller on ebay.de??

[Jaymz]

Nice one, i think one of those is definately on the cards. Hmm soon

[Logzy]

What model is the S wheel off (how was it worded on ebay), its got a GLI badge on it.

I want one so bad but that seller doesnt appear to have another.

[Greg Roles]

Yep it's from e-bay.de, It came with a GLI badge ( weird! ), but a simple swap to the GT one. It is a DSG wheel, so I'm stuck with the cutouts at the back, but hardly a huge issue given both the cost, and how great it looks. If you get stuck with a manual one I'm happy to work out a swap.

That seller seems to get stock from some sort of wrecking yard, and what he lists varies week to week, the wheel looks very new, even if it has been used.

Swap was a little tricky, you'll need a mirror to get the airbag clips, and a just below 10mm allen to get off the steering bolt. I had to grind down a spare 10mm with the angle grinder. Worked perfectly. Elsa doesn't show either of these tricky bits very well, but it sure saved me breaking something!
Quite easy otherwise.

Can't wait for the next drive!

[Logzy]

Yep it's from e-bay.de, It came with a GLI badge ( weird! ), but a simple swap to the GT one. It is a DSG wheel, so I'm stuck with the cutouts at the back, but hardly a huge issue given both the cost, and how great it looks. If you get stuck with a manual one I'm happy to work out a swap.

That seller seems to get stock from some sort of wrecking yard, and what he lists varies week to week, the wheel looks very new, even if it has been used.

Swap was a little tricky, you'll need a mirror to get the airbag clips, and a just below 10mm allen to get off the steering bolt. I had to grind down a spare 10mm with the angle grinder. Worked perfectly. Elsa doesn't show either of these tricky bits very well, but it sure saved me breaking something!
Quite easy otherwise.

Can't wait for the next drive!

Mate. That wheel with the DSG cutouts is really not suited to your car and should be immediatly removed. You cant have two big ugly holes in the back of your steering wheel.
Please package it well so it doesnt get damaged in transit to my place.