Badger5EM Tuning

View Poll Results: Have you kept or removed your EGR?

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  • Removed EGR and blanked off.

    19 65.52%
  • Cleaned EGR and re-fitted.

    10 34.48%
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Thread: EGR - remove&blank, or clean&keep?

  1. #41
    DALE_AVANT's Avatar
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    So, to prevent the EGR from opening and letting exhaust gasses into the inlet, the vac pipe that runs to the black plastic part of the EGR need to be disconnected at the EGR end? Then blanked with a tee/screw?

    Is it then worthwhile to fit a blank plate at the opening of the EGR pipe at the turbo end and another at the EGR end?

    Allard kit sounds good but not having anti-shudder or engine cut-off could e an issue.

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  3. #42
    audilad9's Avatar
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    The EGR dose not have a black plastic bit. The top of the EGR is visible through the hole in the engine cover, to the left of the oil filler cap. The hose that goes into this top part of the EGR (also visible, without removing cover) is the one you want to pull and blank its end with a bolt, tee etc.
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  4. #43
    DALE_AVANT's Avatar
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    By 'black plastic bit' I meant the lever that is attached to the EGR. It operates the butterfly valve inside the EGR which I thought is also responsible for letting the exhaust gasses into the EGR?


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  5. #44
    pauldazzle's Avatar
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    Thats the anti shudder valve.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  6. #45
    audilad9's Avatar
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    As above
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  7. #46
    DALE_AVANT's Avatar
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    I knew that

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  8. #47
    DALE_AVANT's Avatar
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    So to prevent the EGR from letting dirty exhaust gasses into the air inlet manifold, it is as simple as pulling the vac pipe from the top of the EGR and sealing it with a golf tee?

    Does the anti-shudder valve still function?

    Is it still worth fitting blanking plates at either end of the EGR inlet pipe to prevent weird gas pressures etc?

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  9. #48
    audilad9's Avatar
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    As you don't need to touch anything else, then yes, the anti shudder valve still works. It and the exhaust gas recirculation valve are separate albeit housed in the one part.

    So yes its that simple.

    The plates are not necessary but allow you to remove the bellowed pipe between exhaust manifold and EGR ensuring all exhaust gases enter the turbocharger/exhaust with no diversions. They also give a handy access to the turbo should you ever want to do the Mr muscle vane clean.
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  10. #49
    DALE_AVANT's Avatar
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    Good info

    Would a small gasket be needed if blanking plates are fitted and the bellowed pipe removed?

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  11. #50
    audilad9's Avatar
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    I think there are different thicknesses of plates, someone else can confirm likely. I am not sure if the thicker plates (3mm) will fit with the pipe in place, ie the studs are long enough, I cant remember without looking. A thinner plate (gasket) would be fine if keeping the pipe on. I have heard on here of other folk fitting the gasket with a small opening in it, to allow only a small amount of exhaust gas through and thus keep the ecu happy, not triggering the management light, however contrary to what some say, my car an 04 did not trigger the light.

    I got these ones (a pair).
    V.A.G EGR BLANKING PLATE 1.2 1.4 1.9 2.0 2.5TDI AUDI SKODA SEAT VOLKSWAGEN VW X2 | eBay
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  12. #51
    DALE_AVANT's Avatar
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    Is there enough length in the current bolts to support those plates, and are they 2mm thick? Did you fit them and leave the pipe in place?

    I think early B6's did not trigger the ECU.

    Also, does the small metal pipe at the top of the EGR need closing off after the pipe is removed?
    Last edited by DALE_AVANT; 29th June 2013 at 22:56.

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  13. #52
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    Just a little note. I just did this to our golf. 1.9tdi 115bhp version.

    its been suffering from boost lag which I had either pinned down to a vac leak, weak actuator or n75 valve.


    today I blocked the vac pipe off the egr and blanked it with a golf tee. I also did the same at the egr end with a small but of vac hose and another golf tee.

    The golf is a 2000 mk4 and no em light came on or code recorded in the ecu. Driving home it did seem less laggy and picked up earlier in the rev range. Now this could be just because its getting cleaner air or the egr was leaking vac pressure and slowing the actuator down until a higher pressure pushes the actuator arm up giving full boost.

  14. #53
    DALE_AVANT's Avatar
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    Nice info Spats.

    So you disconnected the pipe from the top of the EGR and plugged with a tee.......then fitted a short piece of pipe to the EGR and plugged that with a tee to make it airtight?

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  15. #54
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    Quote Originally Posted by DALE_AVANT View Post
    Nice info Spats.

    So you disconnected the pipe from the top of the EGR and plugged with a tee.......then fitted a short piece of pipe to the EGR and plugged that with a tee to make it airtight?
    thats it! Just thought I might as well bung up both sides to make sure there's no air getting in. I suppose you could just cut the pipe and bung both ends but I wanted it totally reversable if the car had any problems.

    back in it this morning so if anything changes I'll post up. I think i'll run like this and if there's no issues I will look into simplifying the vac system and loose the feed to the egr completely. From my understanding I can keep the feed to the anti shudder valve for now but loose the egr pipes.

  16. #55
    DALE_AVANT's Avatar
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    Sounds good. Are you going to fit a blank plate at either end of the EGR Pipe?

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  17. #56
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    Quote Originally Posted by DALE_AVANT View Post
    Sounds good. Are you going to fit a blank plate at either end of the EGR Pipe?
    i might do. I'm hoping to get down to a scrappy and find an egr to dissect and see if I can remove the guts but leave the anti shudder in place and then see about using a blanking plate. But I'm fairly certain that the egr is as closed as it needs to be without the vac feed.

    next thing to try it on is our a4. Being an 03 plate I'm hoping it doesn't monitor the egr and I can get away with the same trick.

  18. #57
    DALE_AVANT's Avatar
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    Sounds like an interesting plan!

    Is the butterfly inside the EGR to do with the EGR itself or the anti-shudder?

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  19. #58
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    The flap (butterfly) is the anti shudder valve as previously mentioned. It is fully open whilst running, it has nothing to do with the engines running, its there to shut the engine down smoothly once the ignition is turned off by closing the flap and starving the engine of air. It can also prevent engine runaway, should for example the turbo seals fail and the engine is fueling itself on oil quickly reaching very high rpm, the best way to stop it then is to cut the air supply, thus preventing the engine destroying itself. I have seen this happen and its a very alarming thing.
    pauldazzle likes this.
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  20. #59
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    should for example the turbo seals fail and the engine is fueling itself on oil quickly reaching very high rpm, the best way to stop it then is to cut the air supply, thus preventing the engine destroying itself. I have seen this happen and its a very alarming thing

    Any advice on what do if this happens in our motors?
    A4 avant b6.1.9 avf 6 speed. Bv43 turbo.uprated fmic. More bhp custom map. Powerflow straight through twin pipes. Allard delete kit. Boost,egt, + voltage gauges. Ball,spring boost controller. Fk silversport coilovers. 312mm brake upgrade. B7 multifunc steering wheel. Full dis. Cruise control. Auto locks. Rs4 rear bumper. Full rs4 grills. Drls + hids. 10inch custom sub + amp. Rear parking sensors. Leds everywhere. Parrotkit full speaker streaming. silver 4d carbon interior.never ending...

  21. #60
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    Keep a big rag in the car and practise taking the top of the air filter off.

    shove the rag into the intake pipe for for gods sake don't let go of it!

    done it before on a old diesel can that decided to eat its own oil during its mot. I didn't do it myself but I was moving a sales car into the shop when it started up. The intake pipe went flat it was trying so hard for air.

    the other way is to stick it into the highest gear possible and hope you can stall the engine

  22. #61
    audilad9's Avatar
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    Agree with Spats, When it happened to me it was on a JCB digger, I had to remove the air cleaner intake and then stuffed a jumper into the intake pipe, the engine kept running though until it compressed flat the intake rubber hose ! Trying to do this whilst the engine is absolutely screaming, remember theres no limit on rpm now as not usual fuel supply, is very scary and possibly dangerous should it throw its internals out or burst a water pipe. The engine I refer to was stripped and pronounced dead with heat damage. As my car has an induction kit and no anti shudder,I know if it happened to me that if trying to wrap the filter with a bag etc didn't work then I would have to just let it kill itself rather than risk being so close to the engine/turbo to undo jubilee clips.
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  23. #62
    deano1978's Avatar
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    so you cant just pull the key out? to kill the engine?
    A4 avant b6.1.9 avf 6 speed. Bv43 turbo.uprated fmic. More bhp custom map. Powerflow straight through twin pipes. Allard delete kit. Boost,egt, + voltage gauges. Ball,spring boost controller. Fk silversport coilovers. 312mm brake upgrade. B7 multifunc steering wheel. Full dis. Cruise control. Auto locks. Rs4 rear bumper. Full rs4 grills. Drls + hids. 10inch custom sub + amp. Rear parking sensors. Leds everywhere. Parrotkit full speaker streaming. silver 4d carbon interior.never ending...

  24. #63
    audilad9's Avatar
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    Well yes if you have an anti shudder valve, although the engine may still be able to breath via crankcase ventilation etc, not sure.
    No if you don't have an ASV as stopping the fuel supply to the injectors isn't enough.
    I don't know if anyone has had a runaway on a VAG tdi ? But I'd imagine it to be rather rare and unlikely just in case anyone is worrying.
    2004 B6 A4 1.9 tdi quattro sport. Ebony black pearl.
    RS6 style wheels. Black diamond drlled and grooved brakes all round, predator pads.
    K&N 57i induction. EGR delete. Custom Remap @180bhp
    S4 alu mirrors. LED lights. Ambient lighting. Factory armrest. B7 aero wiper upgrade. Team Heko wind deflectors.
    German number plates and Ingolstadt surrounds. Tinted lights.

    To do: Fit new wings. S4 brake upgrade. RS4 rarb. Decat. Tint windows.

    Just fitted 235/40/18 Dunlop Sport MAXX RT's, very good !!

  25. #64
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    Engine shudders on shut down without a working ASV. Just fixed mine recently & it's so much better.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  26. #65
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    Quote Originally Posted by pauldazzle View Post
    Engine shudders on shut down without a working ASV. Just fixed mine recently & it's so much better.
    Mine doesn't. I have the Allart delete kit and it hasn't effected the shut down at all.

  27. #66
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    Quote Originally Posted by audilad9 View Post
    I don't know if anyone has had a runaway on a VAG tdi ?
    And they are very impressive to watch especially as there is nothing you can do to stop it apart from watch it blow itself up. I saw a Landrover do it. Im sure there are afew clips on You Tube of it happening.
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  28. #67
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    Quote Originally Posted by DALE_AVANT View Post
    Nice info Spats.

    So you disconnected the pipe from the top of the EGR and plugged with a tee.......then fitted a short piece of pipe to the EGR and plugged that with a tee to make it airtight?
    Should an early B6 take time to adapt to this change to run with the correct air/fuel mixture once the EGR vac pipe is disconnected?

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  29. #68
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    If i use the ebay plate will i need as gasket? also what else would i need to do? - does it need to be wiped from the map?

  30. #69
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    Right guys I'm having my 2.0 tdi remapped next week and was debating whether to remove, blank or leave the egr?
    It's not causing any noticeable problems although think it could idle a bit smoother, what would you lot suggest?

    I have a delete kit but not sure on fitting it now as hear blanking plates do the same thing, also I hear about an Ibiza gasket with a 9mm hole that limits the egr usage works very well.... What to do???

    Thanks
    A3 2.0 TDI S-Line

  31. #70
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    Don't know where you located but I'm in the north east and can map the egr out and add a blanking kit

    2003 B6 Audi A4 Avant. 3.0 V6 Quattro Sport

 

 
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