Being looking at this myself as well with a view to an EGR and CCV bypass at a later date to clean the air intake. Had a quick look at the weekend and couldn't identify the EGR valve (really was a quick look!). Did spot that the CCV was different to the mods shown on this site and briskoda though. Looks like that on the BKD the rocker is different with the CCV on the opposite side. For the EGR it looks like the seal is a simple o-ring as that is what is supplied with the Forge blanking plate. Will probably have a further look at the weekend. Possibly only two allen bolts to remove.
I cleaned mine, and the intake manifold a few weeks ago. I didn't change any gaskets, rightly or wrongly, and it was mildly coked up after 85k miles. It's at the front on the 2.0ltr engine rather than at the back on the 1.9ltr which makes it easier to get to. However, not easier to get off.
I can't remember off the top of my head whether they had Torx bolts or Allen bolts, but I found it easier with a 1/4 inch drive socket set and a universal joint adaptor. If you don't have a set of these then I'd recommend buying one before you start. They're not too expensive really even though I bought one from Halfords at £30. I use it every day though, and it has Torx and Allen bits in it.
If you get as far as the manifold and decide to take that off aswell, then there's all the bolts you can see and then another inside the manifold itself. You have to stick your Torx / Allen key inside the inlet of the manifold to undo the last one.
I can't remember off the top of my head whether they had Torx bolts or Allen bolts, but I found it easier with a 1/4 inch drive socket set and a universal joint adaptor. If you don't have a set of these then I'd recommend buying one before you start. They're not too expensive really even though I bought one from Halfords at £30. I use it every day though, and it has Torx and Allen bits in it.
If you get as far as the manifold and decide to take that off aswell, then there's all the bolts you can see and then another inside the manifold itself. You have to stick your Torx / Allen key inside the inlet of the manifold to undo the last one.
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This sounds like a good thing to do. Is there anything to watch for when you have a crack at this?
The Forge blanking plate sounds intriguing. I'll have a look on their site.
Any how tos posted anywhere on this one?
The Forge blanking plate sounds intriguing. I'll have a look on their site.
Any how tos posted anywhere on this one?
Just had a look on the Forge site and saw an egr blanking plate for the Audi, which looks the right size for our car, but what happens to the other half of the system that was connected in the first place?
Couldn't see any explanation of it there.
Couldn't see any explanation of it there.
I am not too sure about the blanking plate as yet there is not much in the way of showing how this is done. I have read on the forums it is better to put a blanking plate on the EGR pipe work but have a 4mm hole in the middle. I suppose the valve itself may show up a fault if it is totally blocked off.
Same with if you fit an Allard power pipe. this removes the egr valve totally will definately show up a fault as our BKD engines have an electrical plug on the EGR valve. apparently some tuning companies can remove the fault with a remap but not heard if VAG-COM/VCDS could do the same.
there are a number of TDI site that whow how to do it though I have not as yet seen one for the BKD engine.
Same with if you fit an Allard power pipe. this removes the egr valve totally will definately show up a fault as our BKD engines have an electrical plug on the EGR valve. apparently some tuning companies can remove the fault with a remap but not heard if VAG-COM/VCDS could do the same.
there are a number of TDI site that whow how to do it though I have not as yet seen one for the BKD engine.
The electrical plug is for the antishudder valve which is connected / part of the egr valve, that's all. It just closes the shutter plate when you turn the engine off to stop airflow and aid shut down.
Yes that's the one. The blanking plate will stop the egr valve from allowing exhaust gas into the intake, but the ecu will see the fault and register as such (light on the dashboard). A small hole will reduce the amount of egr and possibly alleviate the light / error but size of hole I couldn't guess. Someone mentioned 4mm, but that might've been applicable to the edc15 ecu on the 1.9 engine.
If you stop arsing about and get a remap then your tuner will be able to turn off the egr when he does it. That's the way forward I think. Best of both worlds.
If you stop arsing about and get a remap then your tuner will be able to turn off the egr when he does it. That's the way forward I think. Best of both worlds.
If you stop arsing about and get a remap then your tuner will be able to turn off the egr when he does it. That's the way forward I think. Best of both worlds.
Already stopped arsing
.... remap already done, though I only need them to send me a new map with egr fault fix and then do it myself via ST3.
Mine was remapped some time back, I'll have to get in touch with Celtic and see if they did that as part of their remap.
If you stop arsing about and get a remap then your tuner will be able to turn off the egr when he does it. That's the way forward I think. Best of both worlds.
quick update, the company who have chipped my car are able to remove the EGR check light. I shall be doing the Power Pipe Upgrade in a few weeks, and will post the findings and "how-to" then.
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Interesting info on, how has your fast road map been? mine is more eco than the eco map! lol
Interesting to see how this goes anyway! need lots of pics!
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fast road map been great really impressed. got a few other peeps interested in NI about the chip as well. The guy from the company said they will do both maps to remove the CEL light so i can then put in the EGR Pipe.
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I checked with Celtic and they didn't remove the egr as part of their map, as they didn't want issues.
I think I will opt for the custom plate with 4mm hole to start, and then enlarge as necessary if I come across any issues.
I think I will opt for the custom plate with 4mm hole to start, and then enlarge as necessary if I come across any issues.
Right , I took of the egr valve and anti shudder mechanism today and OMG what a mess inside!
47k miles so far. I'm amazed the egr worked at all. When I first took it off, you couldn't make out what shape everything was inside it was so clogged up. Cleaned it all out, and made up a plate out of aluminium for the egr inlet, not a full blank off, but a 4mm hole in the centre.
I didn't go as far as the inlet manifold this time, a bit gummed up on the inner surface, but not blocked or anything.
Cleaned the maf and housing with carb cleaner also.
I figured something was needed since last tank saw mpg down to a new low of 25mpg!!
All re assembled and runs nice and smoothly, will report back on how this goes longer term.
47k miles so far. I'm amazed the egr worked at all. When I first took it off, you couldn't make out what shape everything was inside it was so clogged up. Cleaned it all out, and made up a plate out of aluminium for the egr inlet, not a full blank off, but a 4mm hole in the centre.
I didn't go as far as the inlet manifold this time, a bit gummed up on the inner surface, but not blocked or anything.
Cleaned the maf and housing with carb cleaner also.
I figured something was needed since last tank saw mpg down to a new low of 25mpg!!
All re assembled and runs nice and smoothly, will report back on how this goes longer term.
Well nearly a week in and all seemed fine until today. Got an engine check light come up, so I am guessing that the 4mm hole was not sufficient after all. I have removed the plate, but the warning light is still lit. Guess I'll have to find someone with VAG.com to clear the thing. Tried disconnecting the battery, but it made no difference to that. Rats!!
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