LovinPSDs
Veteran Member
Is no one interested in this info?? Or has anyone done this??
Seems like a straight swap would be a great idea assuming you've tuned out the CEL problem.
CR140 Flapper Valve Performance...
- Thread starter storx
- Start date
Is no one interested in this info?? Or has anyone done this??
Seems like a straight swap would be a great idea assuming you've tuned out the CEL problem.
1972SS454
Veteran Member
Ha ha...I guess not Eh?
Well, I just dove right in to the intake manifold flap removal....plenty of time on your hands when u are already in this far...
Stock turbo decided to crap out @ 120k....luckily the Eurojet FMIC core design was sufficient to catch all the shrapnel from the comp wheel. Taking advantage of the situation and installing GTB2060VKLR, Peloquin LSD, and Clutchmasters 18lb SMF with FX400 8-puck clutch while i have her apart.
Intake manifold flaps are gone and I have deleted the ASV and HP EGR valves. Forgot to upload pictures earlier, but will update later.
Oh, and pulled the intake manifold off without disturbing any fuel lines
Last edited:
rix337
Veteran Member
Alright, so I got the Malone Stg II tune for my car yesterday. Mark was nice enough to send along to my installer the additional file to delete the intake flapper sensor as I mentioned it to the installer when I made the appointment. What a difference in drivability with this tune. Pulling out into traffic, I have much more confidence and the low rpm lag you get stock when you didn't quite fit the speed to the gear is not near as bad. Bonus...no Check Engine light on my dash, worrying my wife daily anymore. Thanks to Mark for doing this free of charge. Now my flaps are open and no worries. I will at some point, take off the intake and remove them.
I have a Malone stage 1 tune and removed my DPF and replaced it with a Buzzken DP. I plan on getting the stage and DSG tune, as well as the rest of the exhaust system soon.
I notice a lot of y'all in here have the 6speed tranny. Does it make a difference for those of us with the DSG? Or is it all the the same?
It baffles me at how little the gaskets were discussed? Maybe i'm just stuck with old school ideals but I've ALWAYS replace gaskets when such parts were removed for any reason. Has gasket technology improved that much? Or am I missing something here?
It appears to me that deleting the EGR would be easiest when doing this flapper delete/mod and that deleting the EGR does nothing more than removing it. Like when 1 does and EVAP/SAI delete for the mk4 1.8t petrol engine. Am I right?
I notice a lot of y'all in here have the 6speed tranny. Does it make a difference for those of us with the DSG? Or is it all the the same?
It baffles me at how little the gaskets were discussed? Maybe i'm just stuck with old school ideals but I've ALWAYS replace gaskets when such parts were removed for any reason. Has gasket technology improved that much? Or am I missing something here?
It appears to me that deleting the EGR would be easiest when doing this flapper delete/mod and that deleting the EGR does nothing more than removing it. Like when 1 does and EVAP/SAI delete for the mk4 1.8t petrol engine. Am I right?
DieselRacer
banned
Your tune will have a dsg tune with it, it is a must for a dsg with stage 2 or 3...replace gaskets, yes, they are cheap...
Thats a double negative.
To upgrade to the stage 2 tune, It's a $50 fee. To get the DSG it's another few hundred.
It is not a must. It's not recommended to have a stage2 or higher without a DSG tune, but it is not required.
cool. Thanks. Do you where all of the gaskets are and do you have part numbers by chance?
Last edited:
LovinPSDs
Veteran Member
Anyone going to try the passat manifold?
LovinPSDs
Veteran Member
Not sure... Been hoping one of the guys that work on these things for a living would chime in, but personally id much eater swap the manifold than pull all the parts an leave the rod in there.
A5INKY
Vendor , w/Business number
Some things are considered a given, like new gaskets and TTY bolts when a part is removed and replaced.
With your DP and tune you have a functionally deleted LP&HP EGR system now. You can take associated parts off the car if you want but it is optional.
Not true. Even your stage 1 tune is mapped for more torque than your OE DSG's torque limiter allows. You would have more power from your tune with nothing but a DSG tune added to your current set-up. Due to the DSG software torque limiter's ability to override ECU mapping, it IS required to tune the DSG if you want the benefit of your tune. Malone's stage 0.5 is the only CR140 tune that won't trip the DSG's torque limiter. Anything higher will be a limited by an untuned DSG.
That's what I was taught. But every other DIY I've read had "replace with new gasket here and there" as part of it. When this didn't have it, it kind of threw me off.
They still have to be tuned out or they will throw a code.
I wasn't saying it's not needed to take full advantage of the ECU's tune, I'm aware of the DSG 258 ft/lbs tq limit. I was speaking just from a structurally integral point of view. That nasty clunk that happens with tuned ECUs and untuned DSGs is bound to actually break something. My guess and major tuner's guess that the limit is with stage 3 tunes.
kjclow
Top Post Dawg
- Joined
- Apr 26, 2003
- Location
- Charlotte, NC
- TDI
- 2010 JSW TDI silver and black. 2017 Ram Ecodiesel dark red with brown and beige interior.
I thought early in this thread it was mentioned that the passat and Jetta flaps are different.
LovinPSDs
Veteran Member
Post 248 in this thread is the only mention of this at all and then not a single person besides myself mentions it again. So unless I missed it there is one post saying it would work and nothing else. I'd like to know of it does indeed work, a straight swap and Malone tuning around it would be the best case senario I would think. I guess you can get really close to the same results by pulling them all out and putting the rod back in, but a clean unblocked at manifold would be best.
LovinPSDs
Veteran Member
Sorry I misunderstood what you wrote from my previous response. What I've read thus far is that the passat has NO FLAPS, not different flaps, but thy ARE the same manifold. This is what I'm attempting to confirm. If this is correct, I'd say just swap manifold and sell the Jetta one to recover some of your money.
1972SS454
Veteran Member
http://www.ebay.com/itm/151332252232?_trksid=p2059210.m2749.l2649&ssPageName=STRK:MEBIDX:IT
cheapest i found.
I wasnt able to find the gasket that seals between the plastic and aluminum sections of intake manifold sold separate from entire manifold. The two pieces dont need to be separated to delete the flaps, but does need to come apart to clean all the EGR soot out of the manifold. My gasket was in good shape after 120k....reusing it.
1972SS454
Veteran Member
Once you remove the flaps from the rod u can just pull the tabs off the rod and plug them and reinstall. The rod is two pieces...flap section separate from piece that penetrates side of IM. No reason to stick the rod back in.
I would suggest just modifying your existing manifold. Pretty straight forward and simple. Really the only portion of your stock manifold that people would want to buy is the flap motor (which unbolts from manifold)...if their stock one dies...since they are not available separate from manifold (OEM at least). I have already sold my flap motor since removing it.
1972SS454
Veteran Member
This really isnt a DIY....more a learn as we go.
What A5INKY was saying is that when u get your DPF delete/EGR delete tune....the functionality of the DPF and EGR control valves, temp sensors and pressure sensors are removed. AKA... ECU will no longer look for them and will not throw a code when gone. Then, u can remove all the associated components...like i have...and have no codes thrown.
1972SS454
Veteran Member
Your HP/LP EGR should already be tuned out since u have DPF delete tune...unless u elected to keep your EGR. Easiest way to tell is to unplug the electrical connector from the HP EGR control valve and see if u get a code.
There are two types of mechanical HP EGR deletes. One is a block off gasket that u can bolt between HP EGR valve and pipe. Other is HP EGR control valve delete pipe which removes the valve. Second is better in my opinion...since flow path for intake air through the HP EGR valve is pretty restricted. Diesel Dubs sells both types.
Killabee228
Veteran Member
HP EGR delete from DieselDub. Les just imports the DarkSide Developments race pipe. Cheaper than importing it too.
Makes sense.
I understand that. But I only opted to have the DPF deleted as I only got a straight pipe and we were running short on time so I didn't get the EGR delete done.
Thanks for the link for the gasket btw. Just ordered it.
I'm diggin this. Is that a pic you took from your engine?
Last edited:
Killabee228
Veteran Member
Did you notice any difference with it or is it one of those small unnoticeable, but measurable, add ons?
I'll be ordering that for my EGR delete.
Killabee228
Veteran Member
Malone seemed to have removed the coding for the EGR system when I did the DPF delete. So when I unplugged the EGR motor up front nothing changed. The valve is fully closed. So I didn't really see any difference in power or fuel economy. More or less just ordered the kit to get rid of the useless parts.
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Killabee228
Veteran Member
Hmmmmmmm..... Maybe like 2mpg???
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Really? Not what I expected, but still cool. I appreciate your input.
Killabee228
Veteran Member
See the whole EGR system was already electrically deleted. The flaps were closed from the DPF delete. So adding the pipe and using the block off plate did nothing. But remove parts that weren't being used.
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
LovinPSDs
Veteran Member
Does anyone know where I can see some good diagrams of exhaust flow and really the whole engine so I can understand it alil better?
Not sure exactly where all the EGR parts go... But depending, you may see better flow of the exhaust which helps some too.
Not sure exactly where all the EGR parts go... But depending, you may see better flow of the exhaust which helps some too.
Killabee228
Veteran Member
There are tons if exploded views on the internet. Have to kinda piece it in your head. http://www.myturbodiesel.com/wiki/egr-cooler-removal-audi-vw-2-0l-tdi-engine/
I haven't removed the cooler. But, I have heard that you don't need to remove the turbo/exhaust.
Sent from my iPhone using Tapatalk
I haven't removed the cooler. But, I have heard that you don't need to remove the turbo/exhaust.
Sent from my iPhone using Tapatalk