The Evry Mod + Toggle Switch = Smoke Mod (Pics, Vids, & Links)

The Evry Mod + Toggle Switch = Smoke Mod (Pics, Vids, & Links)

**I apologize up front for the poor quality pictures; my camera is crap and was not working correctly all day! But please, do read on!**

There is a 10 photo limit on this forum - Please find other photos in links underneath the displayed photos, thank you!

I have been reading and watching videos about the Evry mod for quite some time now. Currently, I have a Kerma Q-Loader and tune for stock nozzles, so it is questionable if this should work or make any difference what-so-ever. But, regardless of my fears and worst case scenario, I decided to get some electronics and wire this up.

The main purpose for this mod is for me to get more smoke to spew out of the tail pipe, when I want it (flame away, I care not). Prior to this modification, the car's power is good (much better than stock) for a TDI 5MT Jetta with stock nozzles and a decent tune, mufflerectomy, catectomy, ventectomy, snowscreenectomy, DG race pipe, and Southbend Stage 2 clutch. And there is barely any noticeable smoke. So that's a great place to start!

This is not a tutorial, though you could pick up the gist with this thread. This mod is for entertainment, recreation, and testing purposes. I do not run this mod to produce more smoke at all times. Hypothetically, it could be switched on for a moment, to throw a short burst of a smoke cloud for fun.

The effect that I have been looking for can be explained with something like this: http://youtu.be/Aw80dQo6Td0 or this: http://youtu.be/ffhC0QOCuu0

I am using a resistor, 1K Potentiometer, and an On/Off switch all wired in so that this mod can be enabled/disabled with the flick of a switch. Be careful when tampering with things such as this!

First I started off with gathering the info and materials.

From the local Radio Shack I purchased:
-Black 16ga wire
-Connectors
-40w Soldering Iron
-Small Gauge Solder
-A Small On/Off 2-Position Toggle Switch
-330 Ohm Resistors
-480 Ohm Resistors

Then I sourced a 1k Ohm Potentiometer online - http://www.amazon.com/gp/product/B0002KRE1G

Then I learned how to wire the potentiometer up from this - http://www.ehow.com/how_5887749_wire-potentiometer-variable-resistor.html

So, I followed the instructions and bridged terminal #1 and #2, here you can somewhat see:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2281.JPG



I did not want the pot to have the ability to run down to 0 Ohm, so I decided to wire in a 330 Ohm resistor (low, yes I know) in-line with the pot off of terminal #1 from the pot, terminal #2 (middle terminal) is unused, just bridged with terminal #1. This wire will be spliced with the #2 wire of the fuel pump wiring harness:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2294.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2304.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2312.JPG

After that, I followed the instructions and wired a single wire to terminal #3 on the pot. This wire would go straight to the On/Off 2-Position Toggle Switch. Have a look:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2317.JPG

After getting that all wired up, I found some inspiration and information on wiring up this switch and potentiometer in the car from the following threads:

Classic Evry Mod Information Thread - http://forums.tdiclub.com/showthread.php?p=120184

Additional Info Simplified here - http://forums.tdiclub.com/showthread.php?t=68004&highlight=evry

This guy made a very helpful Video (even though he spelled Evry wrong) - http://www.youtube.com/watch?v=huBFcVIxCPw

This is an ok video for Potentiometer placement and a decent demonstration of the pot setting - http://www.youtube.com/watch?v=Hp4CGMPw7pw

After observing the information and type of installs from the above videos, I found a place to put the potentiometer under the hood:

(sorry for the headlight restoration kit compound splatter)




(FYI the drilled hole in which the wires to pass through was sealed with RTV silicone)

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2320.JPG

Once that was mounted, I started to run the wires. I ran the wire with the in-line 330 Ohm resistor and the 1K Potentiometer (which was the wire coming from terminal #1 on the pot) to the #2 wire of the fuel pump wiring harness. The terminal #3 wire on the pot would be sent into the car, through the grommet above the brake booster, to the On/Off 2-Position Switch. Then a straight, un-tampered second wire, would be run from the On/Off 2-Position Switch, through the firewall, to the #3 wire of the fuel pump wiring harness. This can be seen in the photos below:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2323.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2325.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2326.JPG

Here are a few images of the small On/Off 2-Position Switch:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2333.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2330.JPG

And the On/Off switch wired up:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2336.JPG



http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2348.JPG

Then I began to splice the wires:
(again, if you are unsure about how to do this, please look at the threads and videos referenced above)

CORROSION I KNOW!!! AHH!!

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2349.JPG

Then solder them up:



Then Wrap it all up:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2356.JPG

There you go, hardly noticeable:

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2357.JPG

http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2358.JPG

The finished dash switch (with temporary troll face):




On to the results!

This mod did not have as much of the effect that I had desired. I somewhat expected this by only having stock nozzles and already having some type of tuning in place. There was not an increase in performance or smoke with the current tune and the Evry Mod enabled. I assume that the increased airflow and timing make up for the increased fuel output. Therefore, there was no change in smoke production. I probably should have done a bit more homework on the subject.

So what I did was, I flashed my car back to the stock tune. After this, testing the Evry Mod was like a night and day difference in power. It was not INCREDIBLE, but 100% noticeable. When under acceleration, I would flip the switch and if felt like this: http://rsxisfaster.files.wordpress.com/2007/05/scootervtec.jpg - Not a huge deal, but I can certainly see the desire to do the Evry Mod with these completely noticeable results at such a cheap cost!


There is a video of the potentiometer being adjusted: http://www.youtube.com/watch?v=syoYkrGCtlA


Here are some contrast and comparison videos, you can notice a slight difference in smoke, though nothing crazy:

Rev up smoke puffs: http://www.youtube.com/watch?v=8lMFzW_yET0

Evry Mod Disabled: http://www.youtube.com/watch?v=vRf2lD9RwP0

Evry Mod Enabled: http://www.youtube.com/watch?v=bg5Oi12YIvY


After taking the time to do this, it really didn't have much effect with stock nozzles and a tune. But I certainly noticed a difference in power and smoke after reflashing my ECU for the stock tune and re-testing the Evry mod. I am glad that I have this installed. It was fun to do and I got a kick out of writing this up. Maybe later on in the future, with other tunes, it will have a different or increased effect, or maybe even increase my smoke output on demand. I'm also happy that I did this work in a fairly clean manner.

Thank you all for reading this. I hope it was entertaining, even a bit inspirational, or informational. But mostly entertaining.

***DISCLAIMER***

Please read this disclaimer, as I am not liable or responsible for malfunctions and/or damages caused to your vehicle. http://www.tdiclub.com/Disclaimer/Performance.html



**Extras**

Video outtake, yes I said dude: http://www.youtube.com/watch?v=13L-Aie8ID4

Obligatory mileage shot:
209K and still strong, also 615 miles with 1/4 tank left! http://dl.dropbox.com/u/12313858/Cars/Mk4_Jetta_TDI/Evry_Mod/IMG_2339.JPG

rocketeer928 said:

Someone has too much time on their hands. Ha, ha! At least you are having fun.

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Haha, this actually took me about 3 weeks start to finish. This was more about making a quality post.

damn richard. you need a hobby.

POS VW said:

damn richard. you need a hobby.

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Looks like he has one.

whitedog said:

Looks like he has one.

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yeah buying perfectly good cars, swearing off modding them, modding them. blowing them up and selling them, only to do it again with something more expensive.

Tomato - tomatoe. LOL!

Richard, I won't ever need that information, but It's great that you took the time to do it, then post it. That's a lot of work.

hunter121 said:

I think that's awesome. Makes me feel layered. Like some sort of epic lasagna

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mmm Lasagna.

Awesome write up, I will be doing this mod very soon. The pictures step by step help tremendously!

Mine smokes more than that every day without the Evry mod.

You are welcome... my car had always had virtually zero smoke. Which is good. However, now that I have some DLC1019's I can certainly see some smoke.

I'm about to do this mod but it seems that the engine shaking violently over time would damage the motor mounts has anyone had this problem or are they built to be able to handle it?

Thanks

That is only at idle and the mounts should be ok. It would be better if as you noticed the engine shaking, back off of the resistance a little until it is not or just barely. Then go for a ride and see if you like it.

PhunkFX said:

That is only at idle and the mounts should be ok. It would be better if as you noticed the engine shaking, back off of the resistance a little until it is not or just barely. Then go for a ride and see if you like it.

Click to expand...

Thanks i have already installed the Evry mod and i am currently running around 850 OHM and there is no shaking at idle but it does shutter after i accelerate and am coasting

If more smoke is what you seek, try cranking it up ever so slightly higher than you do in your adjustment video. Then shift early and punch the throttle at ~1-1.2k RPM for a nice thick cloud. Make sure you don't exceed 2k rpm with this method, or you are liable to overboost! The higher you can crank the pot without it stalling, the more smoke you will get. You may also want to try a valve that will limit the boost pressure. Less air + more fuel = more smoke. Good luck and be careful!

What if I wired just a resistor?

That will work perfectly fine as well. It will just be switched on all the time. Many people do it that way.

I better wait to order a pot. I want an on/off switch wired in as well.

travism said:

I better wait to order a pot. I want an on/off switch wired in as well.

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You dont need a pot to have a on and off switch. you an have a resistor and a on and off switch. The pot is just to be able to adjust the ohms without having to switch out resistors.