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

[kolll]

Hi.
204k.
Yes.

mine is at 185k no valley leak yet

 

[commedeschatons]

mine is at 185k no valley leak yet

Thats... beyond lucky.

 

[TurboABA]

Thats... beyond lucky.

Km not Miles.... just in case you missed that.

 

[oilhammer]

Lucky... only in Metric.

 

[TurboABA]

Or more than likely, just unaware as of now.... since you really have to get in there with a borescope to see it, and I suspect that if you have your vehicle serviced at the dealers, they just top off the coolant during service and don't say a thing. Mine took a full 4 years of ownership without the coolant being topped off to notify me of low coolant... which caused me to go looking for evidence in the vee.

 

[commedeschatons]

Or more than likely, just unaware as of now.... since you really have to get in there with a borescope to see it, and I suspect that if you have your vehicle serviced at the dealers, they just top off the coolant during service and don't say a thing. Mine took a full 4 years of ownership without the coolant being topped off to notify me of low coolant... which caused me to go looking for evidence in the vee.

With that many miles, I'd anticipate smelling it rather than having to look. Ive seen cars with 110-120k miles valley filled to the brim with coolant, even with fried alternators from coolant pour down the front of engine at stops

 

[kolll]

Or more than likely, just unaware as of now.... since you really have to get in there with a borescope to see it, and I suspect that if you have your vehicle serviced at the dealers, they just top off the coolant during service and don't say a thing. Mine took a full 4 years of ownership without the coolant being topped off to notify me of low coolant... which caused me to go looking for evidence in the vee.

no no

the valley is dry - 100%
checked

 

[kolll]

Thats... beyond lucky.

its in km's but still good result or luck
looking to get complete delete and bypass - are all components available from you?

 

[commedeschatons]

its in km's but still good result or luck
looking to get complete delete and bypass - are all components available from you?

Yep everything in stock

 

[UgoTdi]

If that's the issue, the delete approach won't fix it.... time will tell

Good point the easy places like the housing needs to be looked at first.

 

[commedeschatons]

It appears the GDM kit has a major design flaw which i remembered as i was working on something on intermediate flange.

Because of their "unique" design, they are basically short circuiting the engine block coolant return to the radiator with the EGR coolant loop back to the thermostat.

This is their intermediate flange Below. In the stock application, there is a divider that splits the two paths. One goes into the cylinder head, one goes out.

In GDM's, there is no divider between the circuits that go into the cylinder head and OUT of the cylinder head to the egr cooler. . If you look at the coolant circuit diagram, they essentially molested the flow and the engine block circuit will not flow correctly as it is merges the circuits going to radiator and and egr circuit going to the thermostat.

In below diagram, egr cooler is item#8, bypass valve is #9. If we short these together the coolant circuit is ****ed.

They could have avoided this in design potentially, but it would have been difficult. They may have known and chose chose to ignore it so they would have an easy place to cross drill and plug. I find it hard to believe you would see two holes that are separated on both the block and the flange and not take a second to think about why they are seperate.

Of course it is always funny to talk about this product because it both existed and didn't depending on when you talked to them if you managed to, as their business principles are essentially heisenberg's uncertainty principle.

Anyways you should never buy GDM's anything if you value your sanity, money, or your car. the end. It turns out they did us all a favor by being impossible to do business with.

 

[BroDave]

This is a great thread. I have learned a ton from those who have gone before. Just found out today I have a plugged exhaust filter. VW said $3-4000 minimum. Only real answer is to do a complete delete as I see it (egr, egr cooler, exhaust filter, and def system). I hold the distinction of being rather mature and don't get what has to happen to the computer to make all of the codes go away and for the engine to run again. In limp mode now.

 

[TurboABA]

Start a discussion where you provide your details with scan results, and someone will help you.

 

[BroDave]

VW did not give any actual scan results just said the exhaust filter was plugged. My scan tool is an obd 2 and is about 20 years old. Should I get a VW compatible tool and if so what one?

 

[TurboABA]

What do you think? Do you want to blindly throw parts at it? Do you want others to blindly suggest parts that you can throw at it?

 

[BroDave]

TurboABA
I've read this entire thread before joining this forum and have seen that you have significant experience and knowledge that you freely disseminate. I would recommend however that you would be even more successful in your correspondence if you would maintain a respectful tone. I asked what tool would you, or other members of the forum recommend?

 

[TurboABA]

Noted

 

[RexNICO]

VW did not give any actual scan results just said the exhaust filter was plugged. My scan tool is an obd 2 and is about 20 years old. Should I get a VW compatible tool and if so what one?

The go to scan tool among the VW/Audi owners I know is the Ross-Tech VCDS. The connector/cable for your era car is VIN limited, so unless you own multiple VW/Audi’s or have friends that do, a 3-VIN cable should suffice. Thanks

 

[BroDave]

The go to scan tool among the VW/Audi owners I know is the Ross-Tech VCDS. The connector/cable for your era car is VIN limited, so unless you own multiple VW/Audi’s or have friends that do, a 3-VIN cable should suffice. Thanks

Thank you. That is most helpful.

 

[av8r]

...bump

 

[commedeschatons]

...bump

what are you bumping for XD

 

[commedeschatons]

well since im here ill drop some new pics of the 1-pc intermediate flanges.
1:1 match with stock hose barb including cutout for hose seating. CNC guys absolute killed it.

 

[craigldavis]

You can do it piecemeal with malone no problem. you only pay the difference in cost on tunezilla.
thats exactly what i did on my touareg. I had egr off only. then my adblue ****ed up and i did egr+adblue off.
Then i did dpf delete and did everything off.

swirl flap doesn't matter.

Did you need to disconnect anything on the EGR Cooler or EGR system with the tune disabling EGR for the time period before you did the block-off and actual bypass?

 

[commedeschatons]

Did you need to disconnect anything on the EGR Cooler or EGR system with the tune disabling EGR for the time period before you did the block-off and actual bypass?

No.

 

[dsnover]

Reviving an older topic. Big thumbs up to SUS TDI, Malone, NAT Performance. Each has contributed to my A6 and Q7. Hoping all parts arrive by the weekend for my A6, so I can complete the improvements. Re-seal, EGR cooler delete, pipes, and a stage 2 tune. Waited for SUS TDI to get some parts in, but now on their way. I'll report the results after everything is buttoned up.

 

[Serega]

This is how i found out that my EGR cooler had an internal leak.
I recently got this new to me 2015 Cayenne. The selling dealer informed me that the oil cooler gasket has been replaced and there was no other leaks. On the drive home I realized that there are two issues, diesel exhaust smell coming from somewhere under the hood and the low coolant warning came up, only added half a liter of coolant, warning gone. I chased the exhaust smell to a cracked EGR tube, from turbo to EGR valve, ordered the parts, so now I was looking for a coolant leak after I saw dry coolant residue flung all over the front of the engine. I pressurized the system and even though pressure was slowly dropping I couldn't see any obvious leaks or drops. Thinking it was leaking somewhere in the engine valley, I looked but couldn't see any coolant ether, I almost gave up looking further, thinking that all that dried up residue was from an old leak and maybe after the work the mechanic did the system burped and that's why low coolant warning came up. I decided to take the intake off to look in closer, I take the charge pipe off and I see that the EGR tube from EGR cooler to intake is completely filled with coolant. I took some of the coolant out of the pipe, pressurized the system again and can see the fluid level rise again, definitely leaking internally. To be honest I was thinking worth case scenario, blown head gasket, cracked head/block or something like that, before I saw that.
https://forums.tdiclub.com/index.php?media/img_3342-jpeg.165581/

IMG_3341.jpeg

forums.tdiclub.com

https://forums.tdiclub.com/index.php?media/img_3337-jpeg.165583/full
https://forums.tdiclub.com/index.php?media/img_3344-jpeg.165580/

I'm just glad I didn't give up and tried to start the engine with all that coolant in the intake, it could have been a bad day.

What options do I have now?

Is deleting EGR and tuning be safe/possible without deleting DPF?

Since I physically have to remove the hardware, it would not be possible reverting to stock tune every time my vehicle has to go through the inspection? I live in New York, so I have to go through the annual State vehicle inspections. Does anyone in NYS has experience with EGR delete and tune, going through State inspection?

Buy the EGR cooler and all necessary parts and put it back to stock?

Financially I think, it will cost about the same deleting, or buying all the parts.

 

[SC RIGGR]

I just finished a reseal on our 15 Touareg. The Sustainable kit fit great. I disconnected vacuum lines back to the checkvave and only needed one cap. The egr pipe bolts at the turbo needed some MAPP gas heat to loosen. I removed the lowest temp sensor on exhaust to get a small impact driver in to loosen bottom nut on pipe. I'll post some pics soon

 

[commedeschatons]

Is deleting EGR and tuning be safe/possible without deleting DPF?

a tuner friend told me it wont regen with EGR deleted. I would ask tunezilla to be sure.

Since I physically have to remove the hardware, it would not be possible reverting to stock tune

im pretty sure ny state is obd2 which would fail for EGR readiness if you go back to stock tune with a delete. because.

 

[commedeschatons]

Buy the EGR cooler and all necessary parts and put it back to stock?

working on some aluminum pieces for stock application too so ppl can have a little more better reliability if they can't delete ****

also cost-down 1pc flange for delete application.