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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old December 4th, 2017, 08:56   #16
740GLE
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Quote:
Originally Posted by KidFromAkron View Post
So after taking some time to decide how to best spend my money I finally broke down and took my car to a non-dealer vw specialist to get a definitive diagnosis. I was torn initially on whether to just spend the $200 and get a VAG-COM and then just do the work myself (if I can) or go to a specialist and have them use their diagnostics and willingly pay the mark up.
Basically for $55 the shop diagnosed what I suspected: I need to replace the EGR valve air regulator flap.
I plan on doing the work myself because in my research I've found that this fix seems well within my wheel house seeing as how I know lefty looses righty tightey. In researching the actual part I found dap.com to have the oem part for $360 and ECS tuning had it for $357 which was from continental. A few key strokes later I found the same serial number continental part on amazon for $253 with free shipping. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
With the money I save in part mark up and labor I plan on buying the ross tech VAG-COM to use later as I plan on getting at least another 200k miles out of my Jetta.
I'll post pics and updates of the work once the part comes in. Thanks again for following and helping with great input!

EGR exhaust flap?

I have one for sale if you're interested, shoot me a PM

http://forums.tdiclub.com/showthread.php?t=480015
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Old December 4th, 2017, 08:58   #17
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Methinks the problem is not with one of the two EGR systems.

Agreeed, EGR exhaust flaps never threw a GP in my ride, it was always a CEL.
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Old December 4th, 2017, 09:51   #18
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Since we have no DTC, we can really only guess what the issue is with the OP's car.

There are two completely separate EGR systems on that car. Most tuners will either greatly dial back or turn of both EGRs from functioning.

From what information was shared, my best guess is an issue with the intake manifold regulating flap (throttle valve), which is used primarily for high pressure EGR flow control and for smooth engine shut down.
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Old December 7th, 2017, 08:19   #19
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I replaced the throttle body last night. It was easy in the grand scheme, only four bolts. Old throttle body was caked with soot but not as much as I'd expected. One day I'll figure out how to post pics. I think i'm going to clean it up and save it in case this happens again. Worth trying anyway.
Car instantly improved. Better throttle response and power, no more clunky stops of the motor at shut down. Check engine light is still on but no glow plug light. I ordered the VCDS from ross tech and it should be here in a couple days so I'll scan it and clear the CEL.
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Old December 7th, 2017, 09:04   #20
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How to post pics is in my signature below.
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Old December 7th, 2017, 09:41   #21
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So it went from an EGR exhaust flap to a throttle body?
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Old December 7th, 2017, 09:43   #22
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Quote:
Originally Posted by 740GLE View Post
So it went from an EGR exhaust flap to a throttle body?

Well, that is the thing, the semantics of the low pressure EGR is such that the throttle body, intake regulating flap, throttle valve, EGR throttle valve, EGR flow control valve, and probably others I cannot remember, are all one in the same part. Different manufacturers (and different scan tools, for that matter) call the same part by different names. Even the Germans cannot agree. VAG, MB, and BMW all call the same part by a different name.
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Old December 7th, 2017, 18:31   #23
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Thank you oilhammer. Perfectly said.
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Old December 8th, 2017, 17:52   #24
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Quote:
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So it went from an EGR exhaust flap to a throttle body?
The exhaust gas has to recirculate somehow.
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Old December 9th, 2017, 09:59   #25
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Got off shift yesterday morning and the CEL did not come on. Drove maybe 50 miles throughout the day and still no light. Car is running so much better! I accidentally left the part at work so Iím going to take pics tomorrow.
Eventually I plan on registering the car in a non-emissions testing county (somehow) and ditch the EGR completely as well as the DPF and probably the cats. Iím hoping Malone will rework my tune to take this into account without raking me over the coals. Sort of looking forward to my clutch wearing out so I can upgrade and go bigger on the power. Iíve really got my hands full now seeing as how I have a supercharged chevelle thatís nearly finished as well!
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Old December 9th, 2017, 14:37   #26
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Don't think this has anything to do with the tune, feel free to shoot us an email though once you have VCDS and an idea of what's going on.
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Old December 9th, 2017, 21:47   #27
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Quote:
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I thought that maybe the sensors had a tendency to take a dump from the changes. Just spitballing. Guess I'll find out tomorrow. Thanks for the reply.
Even with a tune, the sensors are still functioning exactly how they did before. They measure and report to the ECU what they measured.
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Old December 11th, 2017, 20:47   #28
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Even with a tune, the sensors are still functioning exactly how they did before. They measure and report to the ECU what they measured.
And I figured they would, I just thought that maybe the tune might make the car run within ranges the sensors wouldn't like, hence causing the CEL and GPL to come on. Owain says no...
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Old December 12th, 2017, 01:36   #29
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Any time you bump the power, it seems like the added power can find issues that were there all along, just not severe enough to cause a DTC (fault code) to be set yet. Or maybe the problem just plain old occurred, tune or not.
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Old December 14th, 2017, 11:57   #30
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Exactly, if there's any imperfections in the car, they'll be amplified with tuning.

The strongest example of this in the VW world would probably be Mk4 1.8T tuning. The divert valves and N75s often start showing issues as soon as you throw more boost at them. Coil packs are another common one too, but they can fail if you look at them funny.
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