BRD 2.0 TDI DPF EGR Removal

Matt275 said:
Wow those flaps were nasty. I was in there a little while ago whilst replacing the BRD swirl flap diaphragm as mine had a hole in it. The trouble with cleaning out the manifold it it's shape. Fine from the flap end to clean but the main chamber part is awkward to get anything into to scrape off the crud. My fear was leaving a loose chunk ready to fly into my inlet valves at any given moment.
I was going to soak mine overnight but time didn't allow in the end. I'd say it was average cruddy rather than terrible,
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If the inlet manifold is metal, as opposed to plastic (some of them were), then a lot of people simply burn the crud off first before soaking in fuel or cleaner, Matt. I believe you can also fit the metal inlet manifold form the 140TDIs, that have no swirl flaps too, but I'm not fully sure of that.
 
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B7Tourer said:
If the inlet manifold is metal, as opposed to plastic (some of them were), then a lot of people simply burn the crud off first before soaking in fuel or cleaner, Matt. I believe you can also fit the metal inlet manifold form the 140TDIs, that have no swirl flaps too, but I'm not fully sure of that.
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Yes it's an ally inlet on BRD.
Yep, Darkside do a BKD inlet that doesn't have flaps and has been hydro-blasted clean. Fit and block off the actuator vacuum line.
It's a future consideration for me.
 
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Yeah BKD is the one you want if you don't want the flaps. Cleaning wise... Take manifold off and Mr muscle oven cleaner in it for as long as possible then jet wash it out. I didn't do that though, I just cleaned it and brushed it away as best I could with brake cleaner.

I'm going to buy a BKD one myself at some point.

B7 tourer, I mentioned about the torque specs for the inlet manifold is 10nm. That is wrong, it's actually 22nm. 10nm is for the bolt on the EGR to manifold.

I only done my manifold bolts up to 10nm so I need to get those tightened to 22nm tomorrow.

Car runs a lot smoother now but I aint getting the same mpg, it's less and can't work out why as what I've read after doing EGR and cooler delete with cleaning the inlet manifold it should have improved. The only thing I can think of is because I haven't done the inlet manifold bolts up tight enough and that is affecting the mpg.

Will update once I've done it.
 
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markthenewt said:
Car runs a lot smoother now but I aint getting the same mpg, it's less and can't work out why as what I've read after doing EGR and cooler delete with cleaning the inlet manifold it should have improved. The only thing I can think of is because I haven't done the inlet manifold bolts up tight enough and that is affecting the mpg.
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I haven't read through the full thread, but did you get the car properly re-mapped, Mark, after the EGR delete, not just the EML light on, taken out? I'm not familiar with deletes, but I would assume that could be required too? You could be right though re torque settings.
 
I usually test for air intake leaks (maybe not the best way) but with a very fine mist from my Wurth brake cleaner pump sprayer.
You'd hear the RPM increase a fair bit if it was sucking it in.

Just a small amount and never anywhere near the hot side obviously.
 
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