An actual EGR Delete for All 3.0 TDI Gen2 Engines (CPNB / CNRB / CPNA)

[commedeschatons]

GDM's kit is flawed. dont think about it or consider it.

Here are some photos of the extremely complicated EGR delete Kit i just received, along with installed pictures provided by a friend.
Its for the last generation of VAG 3L ever brought here, including Engine codes CPNB, CNRB, CPNA.
These engines are distinguished by these features: Oil filter in the front, HPFP in the back, plastic intake manifold.
This the ONLY true egr delete available for these vehicles, and the entire purpose was to enable CP3 retrofit kit by saving space where the EGR kit goes due to the placement of the fuel pump on these engines there is no space unless egr cooler is removed.

The only way to order it is by calling German Diesel motorwerks on the phone, the cost is $1270 shipped.
This is a prerequiste for their CP3 kit apparently, which they refuse to sell unless they are the ones installing it. I plan to go there to get it installed just to see what its all about.

Additional benefits include significant space savings under the intake manifold and even above it (massive egr valve goes byebye) which pave the wave for someone to make a much much better intake manifold than the plastic one. No one ever will, but thats our struggle.

1 - Photos of the Kit

Coolant Loop

Blockoff plates for both the hotside (at turbo) and cold side (at intake tube) of the EGR system.

These 2 pieces are where the cost is, and are what actually reroutes the coolant that normally would pass EGR thru the cooler.

The top piece appears to have the little brass thingy to bleed the coolant system.

The Fitting process is kind of straight forward, but the only guy i know personally who got this installed had issues with the green gasket sealing, and coolant was leaking out. When I received my kit and was playing around, i think the reason is that the gasket can roll and get pinched if youre not careful when inserting.

He solved it by having these two piece welded as below, but it might not be necessary unless you pinch/roll that gasket accidentally during install. BTW, if you insert it straight on, not at an angle, i found thats the best way to prevent the gasket from rolling.

2 - Installed Photos

This little wire, if its wasn'st there, would make **** a lot more easy. But it has to be there. Its a coolant temperature sensor, which GDM had to keep in the system by way of this little mounty thing.

You can see the CP4 peaking its head out there.

 

[TDIJB]

This is pretty amazing, the space you gain is awesome and the piece of mind for less leak points. What tune did you use to not get all the codes and all?

 

[calimustang]

following as well.

 

[Tierarzt]

Did you finally get the cp3 installed?

 

[Adobian]

Following

 

[cee_riss]

I ordered and installed this kit on my 2013 Touareg CNRB as well. I paid $1220 shipped. Everything lined up perfectly. Only difference on my kit is that the brass plug doesn't exist on mine. Maybe explains the $50 price difference. I was able to install it without damaging the seals.

Malone stage 2 eco-tune gets rid of the possiblity of the ECU throwing any codes.

 

[TurboABA]

Are you guys dropping this kind of coin on "prepping" for CP3 conversion, or how do you justify the ROI?

 

[Sword_of_the_Spirit]

ROI is a part that will eventually fail (given time). Don’t worry though, you’ll be out of your diesel gate extended warranty by then….I would put half a “k” on it!

Only other individuals doing deletes where some Russian’s. That was custom one-off’s. Otherwise, you get the block off plates from Darkside and leave it disconnected.

Here’s to increased mpg’s and extended oil changes with reduced soot/fuel washing!

Boy, I love going against the grain. People always want to have their cake and eat it as well. Too bad, reality makes sure that doesn’t happen.

 

[TurboABA]

Sure bud... what's this cost? $1200-1300 + custom tune to get your additional MPGs?
How much are you MPGs are you picking up and how much fuel are you using?

 

[Sword_of_the_Spirit]

I am not messing about, and I do not wager that which I’ll lose. Let’s set a date of failure and we will count down as a forum…CAD only mate….I know you want my USD…lol

EGR and SCR/DPF delete yields about 1.6 mpg based upon my calcs. My Wife’s never saw the OE Emiss Update and only drives in Sport. Cayenne we’re talking about… Same Commute for 6mnths pre (28.1) and post (29.7) all in Sport. You’d be a fool to not use it if you have that mode as the extra volume decreases EGR usage (not that mine used much anyway thanks in part to the Genius: Bosch) and keeps the flaps perky.

Diesel which is 53 at cetane level, does help a little bit…..

 

[Dunerking1]

Nice kit! Looking at your pic reminds me I need to order a oil dip stick for our 13 Cayenne TDI.
Besides not passing a visual for our every other year test here in Cali does anything pop up on the OBDII? Thanks

 

[Sword_of_the_Spirit]

Depending on the tune/tuner, readiness monitors will flag. Nut shell, do it if you don’t mind the 3hr put back/forth.

 

[dcapper]

I have a 2013 Cayenne diesel. My EGR completely failed. It sent coolant into the intake hoses. Porsche wanted $1400 just for the EGR. My buddy who is a mechanic said to remove it since I have a stage 2 Malone tune. He had 3 parts manufactured that cost $250 inc taxes. Two block off plates. One is made in steel for the turbo. One in aluminum for the intake. Then the sensor adapter. He bought a Gates 28475 hose and a few hose clamps. Was a lot cheaper. He cut the corner off the EGR cooler so it would connect to the flange. He had two codes when he started it. $0E78 and $0E79. Probably had to do with removing the fuel line from the rail. Cleared the code and drove 50kms. Codes never came back. There is a post on Rennlist about the way I did it.

 

[mannytranny]

Could you link the thread?

 

[dcapper]

https://rennlist.com/forums/cayenne-958-2011-2018/1235978-2013-cayenne-diesel-cd-958-egr-physical-delete.html

 

[Dunerking1]

Good read! Thanks

 

[Sword_of_the_Spirit]

I have a 2013 Cayenne diesel. My EGR completely failed. It sent coolant into the intake hoses. Porsche wanted $1400 just for the EGR. My buddy who is a mechanic said to remove it since I have a stage 2 Malone tune. He had 3 parts manufactured that cost $250 inc taxes. Two block off plates. One is made in steel for the turbo. One in aluminum for the intake. Then the sensor adapter. He bought a Gates 28475 hose and a few hose clamps. Was a lot cheaper. He cut the corner off the EGR cooler so it would connect to the flange. He had two codes when he started it. $0E78 and $0E79. Probably had to do with removing the fuel line from the rail. Cleared the code and drove 50kms. Codes never came back. There is a post on Rennlist about the way I did it.

Can you share with everyone your driving style, miles, and how you maintained for everyone that isn’t a part of Rennlist to here. As someone in the know, it would be great to here it from someone else their experience and what options led you to this solution…..

 

[dcapper]

Well the two codes came back. I have a message out to Malone to make sure my EGR was removed on the original tune.

 

[Sword_of_the_Spirit]

Did you not order the EGR/DPF/SCR delete in the first place? As high of remarks as they get, they do mess that stuff up quite a bit. Had an issue with them as well. QC needs to be implemented.

 

[dcapper]

Did you not order the EGR/DPF/SCR delete in the first place? As high of remarks as they get, they do mess that stuff up quite a bit. Had an issue with them as well. QC needs to be implemented.

my egr failed. Started sending coolant down the intake pipe. I had a stage 2 without the deletes. So we removed it and now ordering the delete program. I have a tunezilla so I can reprogram it myself.

 

[Sword_of_the_Spirit]

Gotcha.

 

[dcapper]

I got my Malone EGR delete code the other day and all the engine lights are now gone. They even gave me the complete delete code too if I decide to remove the dpf.

 

[Philidelphia Collins]

Sure bud... what's this cost? $1200-1300 + custom tune to get your additional MPGs?
How much are you MPGs are you picking up and how much fuel are you using?

I don't necessarily think it's a ROI from fuel savings that would motivate one to do this. The EGR cooler on my CNRB is leaking internally, and I'm already deleted and tuned. EGR cooler alone from VW in Canada is $2150 plus tax. Sure, a bunch of people still have the extended warranty, but I would much rather just completely delete the hunk of junk and not have to worry about future problems. I would not be looking at it from a fuel savings perspective in my case.

I have a 2013 Cayenne diesel. My EGR completely failed. It sent coolant into the intake hoses. Porsche wanted $1400 just for the EGR. My buddy who is a mechanic said to remove it since I have a stage 2 Malone tune. He had 3 parts manufactured that cost $250 inc taxes. Two block off plates. One is made in steel for the turbo. One in aluminum for the intake. Then the sensor adapter. He bought a Gates 28475 hose and a few hose clamps. Was a lot cheaper. He cut the corner off the EGR cooler so it would connect to the flange. He had two codes when he started it. $0E78 and $0E79. Probably had to do with removing the fuel line from the rail. Cleared the code and drove 50kms. Codes never came back. There is a post on Rennlist about the way I did it.

My cooler has been leaking internally and sending coolant into the intake as well. Started out as having to add a bit of coolant every couple months to every few weeks. Since the problem started, I have gone though probably at least 5 gallons of coolant. I wish there were enough competent people around where I am that could fabricate up what your buddy did. Closest TDI mechanic is 3 hours away, and I've been trying to get my Touareg in to get looked at for 6 months with no luck. I wouldn't trust any shop near me with engine repairs, let alone off the cuff modifications lol; so I hope I can get my hands on one of these GMW kits.

 

[qluvr]

Hi @commedeschatons. I've got all me EGR cooler delete parts in hand EXCEPT no means to attach the temp sensor. Can you give me the reference please for the shop that made up your temp sensor adapter please?

 

[jhax]

Good morning,
I am in the process of executing this procedure and I was wondering if 1, a tune was necessary since it seems like the sensors for the EGR remain connected. And if that is the case, did Malone need to bench unlock your ECUs prior to you just loading the tune via the flashzilla?

 

[commedeschatons]

Good morning,
I am in the process of executing this procedure and I was wondering if 1, a tune was necessary since it seems like the sensors for the EGR remain connected. And if that is the case, did Malone need to bench unlock your ECUs prior to you just loading the tune via the flashzilla?

sensors can remain connected or unconnected, doesn't matter. make sure you cap the vacuum line, best place to do it is mainline on driver side that feeds both the bypass valve and egr metering valve solenoids. or you can cap them off individually.

I hope you are not installing this GDM kit because there are 2 other kits at 1/5th or less of this cost now.

 

[commedeschatons]

Good morning,
I am in the process of executing this procedure and I was wondering if 1, a tune was necessary since it seems like the sensors for the EGR remain connected. And if that is the case, did Malone need to bench unlock your ECUs prior to you just loading the tune via the flashzilla?

but yes you need a tune no matter.

 

[jhax]

Can I cap the hose that goes to the solenoid on the V and remove this valve?

 

[Jayhawk94]

sensors can remain connected or unconnected, doesn't matter. make sure you cap the vacuum line, best place to do it is mainline on driver side that feeds both the bypass valve and egr metering valve solenoids. or you can cap them off individually.

I hope you are not installing this GDM kit because there are 2 other kits at 1/5th or less of this cost now.

Where? I’m in the market for one and have only seen this one mentioned anywhere despite repeated searches.

 

[jhax]

So I keep getting codes thrown even after they have been deleted via an AlienTech unit.

Codes you requested off
2425, 1257, 1440, 0405, 040D, 0544, 102E

New codes that you are suggesting we have not turned off.
0401, 1259, 2080

Code off but returning
1440

Possibly because of the 3 new codes. Not sure.

There should not be this many codes. Some sensors may need to be plugged back in.

I have all EGR related sensors unplugged, the one that is in the rear that plugs into the cooler, one that plugs into the first EGT coming out of the cooler, one that plugs into the vacuum valve that goes to the valve behind the cooler and one that goes into the bypass valve that feeds into the cooler and the main vacuum valve. Any assistance would be appreciated.