deejaaa
Veteran Member
yes, you do!Ehhhh... do i must to congratulate you for to be an american?
this will be done on mine as soon as i get around a vag-com person. want the economy tune also.
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yes, you do!Ehhhh... do i must to congratulate you for to be an american?
Im thinking of doing this mod as ive got oil coming from the breather holes. Is the safest method to drill the EGR plunger out and then get a shop to weld the holes up? (I cant weld and id hate driving around worrying about a bolt falling in or out.
Since my EGR has been non functioning since I bought the car (bad N-18 valve), I decided I didn't really need the EGR in there anymore. But I am also a cheap bugger and even though Dieselgeek has a nice looking race pipe, I can't afford one. So I thought I would make one myself by gutting a stock EGR valve. It is cheap and also still retains the anti shudder valve which is something the real race pipe cannot. It also looks stock, thus the stealth factor.
I am doing an intake cleaning this weekend, so I am prepping the SRP to swap in then. I bought a used EGR from another member for experimentation purposes. This is what it looked like out of the box:
Here is after a quick cleaning:
It's a lot less restrictive after the cleaning, but that valve body & plunger are still quite prominent. So I cut it out. I just used a small hack saw to cut through it:
Here is the EGR with the plunger out:
There is a steel insert that acts as a seat for the plunger. I wanted to remove it so I could file down the hump that is there (its easier to file aluminum than steel). I just used a socket that was just slightly smaller than the insert and punched it out:
Here are all the parts removed:
I did some filing to make the inside diameter a little smoother. I also plan to get the hole welded up for a completely smooth inside diameter. If I can't get it welded cheap, I may try JB Weld to block it off. I could just put a block off plate in there, but that wouldn't be as smooth, so I will fill the hole & hone out the inside of the valve once its finished. For now, here are before & after pics:
I posted this in the Performance section because it will allow more air into the intake. Whether it does anything or not, time will tell, but it can't hurt. I know it is environmentally unfriendly to remove the EGR, but as I said, it was non operational when I bought the car, so whats the difference? I also use low sulphur fuel in a B20 mix, so it is not all that bad, is it? I will have my original EGR to swap back in if I need to.
Now I just need an OMI (Oldman Intake) to go with it /images/graemlins/grin.gif
EDIT: Here is the finished product:
DISCLAIMER: This mod is for OFF ROAD use only
I haven't yet.Has anyone in California done this??
How did you go about it?Thus far a sympathetic smog tester has passed my 02 Jetta equipped w/ a racepipe.
My mechanic of 25+ years knows a guy, etc...How did you go about it?
"hey, I got a six-pack with your name on it if...." ?
haha
How did you go about welding that? I'm using a 5352 filler rod, 3/32 ceriated tungsten, 75% wavelength, 120hz and 90 amps. The part should be just regular 6061 right?Thanks! Awesome idea.
Just did this mod myself
Like the idea of tapping and plugging with a bolt but for something that is never going to be removed i wanted something a bit more permanent. And this was just easier then for me to find a bolt and tap.
Machined a piece and pressed fit into EGR then welded everything up.
it's oilsoaked cast garbage alloy, so it'll weld uglyHow did you go about welding that? I'm using a 5352 filler rod, 3/32 ceriated tungsten, 75% wavelength, 120hz and 90 amps. The part should be just regular 6061 right?