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EGR blank & inlet mani clean

Discussion in 'A4/S4 forum(B5 Chassis)' started by MaverickTDi, Jan 8, 2013.

  1. MaverickTDi
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    MaverickTDi Member

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    [Jan 8, 2013]
    Is there any guide (with pics) that show how to do the above?

    Thanks.
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  3. MaverickTDi
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    MaverickTDi Member

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    [Jan 9, 2013]
    Found a few threads on other forums with alright pics but not 100%.

    I was thinking of buying the Darkside kit, £50, anyone got one?

    Also, is the inlet manifold straight forward to remove?
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  4. B5 BIKER
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    [Jan 9, 2013]
    What's the dark side kit mate?
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  5. MaverickTDi
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    [Jan 9, 2013]
    #4
  6. B5 BIKER
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    [Jan 10, 2013]
    Nice, might have to invest in that
    #5
  7. scr8pdo
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    [Jan 10, 2013]
    Thats^^ a nice site for VAG TDis, gonna have a mooch :)
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  8. B5 BIKER
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    [Jan 13, 2013]
    Think might have to change the manifold for this kit to work.
    it is for the pd engine, but I know that you can put a pd manifold on to
    the AFN block. I stand to be corrected
    #7
  9. scr8pdo
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    [Jan 13, 2013]
    ^They do a kit for the AFN engine too, I think its called the VE one IIRC, its 51mm instead of the 57mm PD one, but as you say you can change the manifolds apparently, I might have read it wrong though ??
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  10. MaverickTDi
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    [Jan 13, 2013]
    This was the link Darkside Developments provided me. I shared the same hesitation as it didn't include 'our' engine code (AFN), they got back to me and said that this kit is compatible with the AFN engine, he just needs to update the website to reflect.

    If your still skeptical I'd just phone them and get a straight answer over the phone and agree with them that if by some unforeseen circumstance the kit doesn't bolt straight on no hassle then you can return.
    Last edited: Jan 13, 2013
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  11. B5 BIKER
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    [Jan 13, 2013]
    Fair enough, might do that when the missus gives me back the card
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  12. TeKnodriver
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    TeKnodriver Biodiesel Purrrr

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    [Jan 14, 2013]
    I've tried and falied twice - the hex-key bolts seem easy to round off on mine even with quality ratchet hex-bits
    tried with a set of the bolt grips for rounded nuts on the outside of said nuts but there's always one that refuses to budge.

    i needed airbox out and pipework removed...

    in the Spring might try with a blowtorch

    you might be lucky though - spray on some plusgas and give it a try?
    #11
  13. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 14, 2013]
    You checked the manifold has the bolted flange for that kit?

    AFN's i've seen i'm pretty sure dont have it.

    For example:

    [​IMG]
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  14. MaverickTDi
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    [Jan 14, 2013]
    Not sure tbh?

    This is what they say on the website Darkside 1.9 8v TDI VE 90 / 110 and PD100 / PD115 EGR Delete / Race Pipe (51mm) - Darkside Developments

    I queried the fitment of the above kit on the AFN engine as it did not specify on their website, I was assured it would be compatible the website just needs amending, I would of thought they know what there talking about?
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  15. TeKnodriver
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    TeKnodriver Biodiesel Purrrr

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    [Jan 14, 2013]
    Looks nice and shiney,
    I cannot see how that kit would fit the AFN without a different or even custom inlet mainfold -
    mind you, as the kit is for PD100/115 perhaps one of those inlets could be used?

    I went with the cheapo 4mm steel plates off ebay and saved the change for a remap...
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  16. MaverickTDi
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    [Jan 14, 2013]
    Well we'll soon see as I ordered the kit tonight, I can't see why it's not a straight bolt on mod? I doubled checked with them before hand by asking do they do a EGR delete kit for a '98 TDi 110 code AFN and they referred me to the above kit, I would expect them to state that if what your saying is accurate I would require a PD100/115 inlet? As this then wouldn't make it a 'bolt on' mod.
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  17. scr8pdo
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    [Jan 17, 2013]

    Can you point me in the direction of the cheap kits on ebay, ie a linky :)

    Iam still waiting to have a go at my inlet decoke and EGR deletion, BTW if anyone is finding undoing the hex bolts hard, a little tip (which works on most bolts including wheel studs) if you can get at it tap it quite firm with a hammer or put a bit in with an extension and hit that hard inwards, nearly ALWAYS works, as for the wheel nuts, place an impact socket over the nut and belt it fookin ard, a few times you will be amazed :) I scrap cars for a living and often come accross stubborn wheel nuts, honestly even some that wont budge with a 4 ft breaker can often be easily undone with a standard brace after a good WHACK! lol :)
    #16
  18. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 17, 2013]
    If you look at what they provide in the kit, then look at a GOLF manifold, you can obviously see where it fits:

    Vw golf mk4 1.9 TDI Inlet Manifold ARL 150bhp 038129713AF | eBay

    Thats a golf manifold, and as you can see has a flange with a massive EGR assembly, which the darkside kit replaces with a nice plain fitting.

    Compare that to the photo of the A4 manifold i posted above, and you'll see that theres nowhere for that flange to go. Instead the A4 has it cast in, and has a seperate external valve.

    All you need for an AFN is two steel plates and two gaskets which should cost less than a tenner.
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  19. MaverickTDi
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    [Jan 17, 2013]
    I see your point and very well presented!

    I have ping'd an email off to Darkside and once again challenged there compatibility of this kit on the AFN engine. Being a new Audi owner and with little engine knowledge on this particular car, I suppose I took confidence in what Darkside told me the 1st time, if this ends up being the wrong kit, which, is looking increasingly likely, having seen the 2 different manifolds and flange in the kit, I guess lesson learned.

    I shall feedback the response from Darkside when I get it.
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  20. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 18, 2013]
    #19
  21. MaverickTDi
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    [Jan 19, 2013]
    Aragorn, you were spot on with your observation, the kit Darkside said would be compatible, dispite me asking for confirmation it was the correct kit, was in fact for a different set up all together. As far as I'm lead to believe the only way you can delete the EGR is to use, quite simply, 2 blankings plates. The kit I purchased feature 1 blanking plate and having justified that this particular kit wasn't correct they said send it back minus the blanking plate, we'll send you another one free of charge and refund you the £50 plus postage expense for returning the kit, so although it was been a little bit of a ball ache to sort it out, I've walked away with 2 genuine blanking plates for cock all, winner!

    My next question, what do people recommend to plug the flexible pipe the comes of the EGR valve itself?

    Thanks.
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  22. TeKnodriver
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    TeKnodriver Biodiesel Purrrr

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    [Jan 19, 2013]
    the stainless flexi-pipe connects the exhaust manifold to inlet manifold via the EGR.
    this pic kindly posted by aragorn shows where to put the plates - one of each of the sets of bolts are visible

    remove this flexi-pipe and keep the bolts
    Most of the blanking plates available simply locate onto each manifold at the point where the flexi-pipe currently sits.

    That's how I did mine anyway, hope it helps
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  23. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 21, 2013]
    I'd remove the EGR valve and the flexi pipe entirely.

    Fit one blank to the exhaust manifold inplace of the flexi, and fit the other blank to the inlet manifold in place of the EGR Valve. Remove the lines to the EGR solenoid and blank them off. You'll need to leave the solenoid connected electrically or you'll get a fault code.
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  24. MaverickTDi
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    [Jan 21, 2013]
    Audi engine.JPG

    So to clarify;

    The 2 areas I have circled yellow is where you blank off?

    My next question is what do you do with flexi pipe coming off the valve itself? Where does the solenoid electrically connect to, location that is?
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  25. ScottD3
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    [Jan 21, 2013]
    The AFN engine is fitted to many different VAG cars, they say it will fit but they might have only used it on a VW AFN engine.

    The A4 AFN engine is different and this kit will not fit.

    For the price of that kit you could buy every AFN owner on this forum a set of blanking plates.

    The AFN Blanking plates that Aragorn posts up are for the AFN generator engines, they don't need EGR vavles so they just blank them off.

    BE warned that most EGR blanking kits will offer you the same size blank for the inlet and exhaust side.
    The Exhaust blank is easy fine, no issues but the the 2nd blank for the EGR side, goes between the EGR and the exhaust side, not between the EGR and inlet.
    The inlet side of the EGR is smaller.
    So you keep the EGR valve and the flexi pipe.

    If you want to go one step further and remove the EGR, you will need a smaller blank, I've not seen theses on Ebay so I made my own.
    The flexi pipe was closed via a bolt and cable tied and hidden in the bay.

    It now looks like this.
    [​IMG]

    What ever blanks you go for, make sure you get a new gasket for both the exhaust and inlet size.
    The ebay and my own made blank for the inlet side will seep oil out. I got no idea why and I've been unable to stop it.
    I've gone through multiple blanks and gaskets and it still leaks.
    I would recommend trying the VAG blanks in the hope this stops the oil leak.
    I will at some point by the VAG blanks once I got my finger out.
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  26. MaverickTDi
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    [Jan 21, 2013]
    From what I understand, I will be getting 2 VAG blanking plates of equal sizes, so going by your recommendations, I will be leaving the EGR valve on but deleting the metal flexi pipe.

    I'll look into gaskets for blanking plates, can't be more that a couple of quid each from TPS?

    On a different note, super clean bay! Is your car PFL or FL, there's a lot of plastic trim in your bay that I don't have i.e. around the washer bottle, over the airbox, scuttle panel and battery cover. Did PFL cars have these fitted? Defo getting some FL headlights, look so much better than PFL!

    Thanks for your reply.
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  27. ScottD3
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    [Jan 21, 2013]
    Thanks. It's still not finished.

    Mine is a PFL, a lot of the plastics are from passats. Check the engine bay thread for part numbers and more info.

    The gaskets are less than £2 from Audi or VW.
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  28. MaverickTDi
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    [Jan 21, 2013]
    I take great appreciation in a tidy engine bay, looks as though you take pride in your car.

    Here my engine bay at present;

    clothes & Audi 028.jpg

    and as you can see, it's missing almost everything!?

    Is the Passat stuff bolt on? Also, I see in the engine bay thread you mentioned 2 bits, PAS cover and airbox cover that you can source from VAG themselves? As you said in that thread they match in design so would be a better choice for continuity but does the airbox cover fit properly?

    Thanks.
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  29. ScottD3
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    [Jan 21, 2013]
    All genuine VAG parts.
    The washer bottle cover needs little trimming for the pipes then it's easy enough.

    The air box cover is ok. It's a little wobble when touching but that's cause our box has not got any clamps.

    I'll get some better pics on wednesday.
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  30. MaverickTDi
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    [Jan 21, 2013]
    Yeah I could see that on your pic, easy enough though.

    Might source the original air box cover, although it doesn't match the Passat PAS and washer bottle cover, it still looks very clean and tidy, like yours.

    More pics would be ace, thanks.

    Now trying to source the scuttle cover and air box cover, should be fun!? Know anyone selling?
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  31. MaverickTDi
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    [Jan 22, 2013]
    I'm after the following engine bay trim for a B5 1.9 TDi;

    Air box cover
    Scuttle cover inc. battery cover and additional bit of plastic that lives in the top right hand corner as you look at the engine.

    If anyone can point me in the direction of the above that's for sale or know someone who's breaking that would be brill!

    I've contacted several breakers on eBay, some don't have what I'm after and some I'm waiting to hear back...

    Thanks.
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  32. ScottD3
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    [Jan 22, 2013]
    Dimple air box cover from Passats. 3B0 133 849 A £21.71
    [​IMG]

    [​IMG]

    Dimple ABS, screen wash cover from Passats. 3B0 119 487 C £37.09
    [​IMG]

    I think most facelift B5s will have the scuttle cover, so any breaker breaking a B5 should have one. Unless he sold it.
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  33. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 22, 2013]
    If you want the facelift battery cover, you also need the two plastic trims that run along the bottom of the windscreen, as they're different to the PFL ones.
    #32
  34. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Jan 22, 2013]
    and the rubber strip.

    Might as well get FL wippers to go with it.
    #33
  35. MaverickTDi
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    [Jan 22, 2013]
    Thanks for the replies guys.

    Will the Passat air box cover, pictured above, securely fit?

    Also regarding the scuttle cover, I understand that I need one from a FL car but how many separate pieces does it have? I can see this being a right pain in the arse to source unless 1 car has everything in need?

    Do I need FL wipers?

    Cheers.
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  36. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Jan 22, 2013]
    The Passat Air box cover fits.
    It's not going to fall off and fall down between the engine. There is a clip on the cover and on the car that matches up and secures it. so no need to worry about it.

    The scuttle cover is 5 parts.
    the 2 plastic bits under the windscreen held in by the wipers, the main long cover, the battery cover and the rubber strip.

    You don't need FL wipers but they look better.
    #35
  37. MaverickTDi
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    [Jan 22, 2013]
    So the PFL wipers will secure the 2 plastic bits under the windscreen despite the scuttle cover is from a FL car?

    I've just placed an order with TPS for the air box and ABS/screen wash cover. £19.51 for air box cover and £33.29 for ABS cover.

    I think it's going to be very difficult to source the scuttle unless I physically go to a scrappy that has everything still in tact, I can see it being complicated to explain the various components via eBay for example.
    #36
  38. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Jan 22, 2013]
    The wipers don't really hold the plastic bits down, its just that you have to remove the wipers to get the plastis panels off.

    I would personally get the parts your self.
    It will give you a better idea of how they come off, you make sure you got everything, no missing clips and less chance of it breaking in the post.
    #37
  39. MaverickTDi
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    [Jan 22, 2013]
    Yeah that's a fair point, cheers.

    Right, start ringing local scrappy's now, fingers crossed!
    #38
  40. scr8pdo
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    [Jan 25, 2013]
    So just to clarify about EGR blanking on an AFN lump, after blanking the 2 holes, I need to leave the rubber hose just blanked off with say a bolt or similar and all will be ok?
    #39
  41. ScottD3
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    ScottD3 I want your faulty electronics Supporter

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    [Jan 25, 2013]
    If you are keeping the EGR valve. lease the hose alone, if you are removing the valve, then blank the hose off.
    #40

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