Vendor , w/Business number
- Sep 24, 2003
- '14 GSW TDI, '11 Golf TDI, '97 Golf Variant Syncro 1.9L TDI, '96 Golf 1.9L ASV TDI, '93 Eurovan Westfalia 1.9L TDI, '09 BMW 335d, '17 BMW 328d
Background: I permanently turned down EGR as far as the ECU could manage in my 2006 TDI. I immediately noticed a difference in 8C/46F weather:
- With EGR turned off right from the start, my engine took significantly longer to warm up. A cold engine is bad for longevity and fuel economy.
- I was losing coolant heat during traffic stops because heat from the exhaust was not being recycled. Even if the coolant temperature was optimal @ 90C (194F), I could see my temperature needle drop below 40C (104F) whenever I tried to leech engine heat for my interior comfort.
After putting the EGR settings back to stock, the TDI is able to build and retain heat with much less effort. I enjoy better MPG too.
Some people with EGR delete report lower MPG during short commutes, and better MPG during long trips. Here's an example from a 2005 PD 1.9L BEW TDI customer in Los Angeles:
He later re-installed his EGR components and his fuel economy shot up back to normal.City/Highway Mix:
All Stock: 42 mpgHighway:
Stock, EGR OFF: 34 mpg
Tuned, EGR OFF: 35 mpg
Tuned, EGR ON: 43mpg
All Stock: 46 mpg (trip to Vegas)
Stock, EGR OFF: 44 mpg (trip to San Francisco)
Tuned, EGR OFF: 47 mpg (trip to Seattle)
I get requests every week to delete EGR completely so I developed a Dynamic EGR tune that may be an attractive alternative for the following reasons:
Reduced Wear and Tear
Cold engines have greater engine wear and it is exacerbated by EGR delete because of slower warm-up time. Even if you live in a hot climate, a little increased wear every day will add up.
Mercedes Benz has also documented increased engine wear caused by EGR (soot abrasion in cylinders), and by minimizing EGR once the engine is warmed (EGR is minimized for the majority of engine run-time), you further reduce overall wear & tear.
Optimal Fuel Economy
Cold diesel engines have a lot of blow-by and once the engine is warmed up, the engine seals tighter and gets better fuel economy. By reducing your engine warm-up time with EGR, you reach optimal fuel economy sooner in every drive.
Emissions with a cold engine is especially dirty. Normal EGR operation during warm-up can significantly reduce your annual emissions compared to a full EGR delete.
Runaway Engine Protection
If a turbo leaks oil into your EGR-deleted intake, the engine may start running on its own. Shutting off the "ignition" key will not stop it because the oil self-burns. It will continue to rev high until potential damage occurs. Or until you shift into a high gear and stand on the brakes to stall the engine. If you get the timing right you'll probably save the engine. Otherwise you're out of luck, especially if you have an automatic transmission.
The EGR has a valve that can block airflow from entering into the intake once you turn the key off, thus suppressing the oil burn and stopping the runaway.
Smoother Engine Stop
This may not be a big deal to some people, but the engine will shake noticeably when turned off, if the intake valves are removed. Retaining the EGR valve (especially for ALH TDIs that don't have an IMF) will maintain smooth engine shut-offs.
Some customers have reported smoother idle with Dynamic EGR compared to stock EGR. If your TDI occasionally has a slight "miss" while idling, Dynamic EGR may reduce or eliminate that issue.
Some customers who still have their stock performance tune have noticed slightly improved low RPM response, especially off the line. That's with only Dynamic EGR as their only modification.
With Dynamic EGR, EGR is activated only during the short warm-up period. It's turned down as far as possible for the rest of your drive. Your intake will be free of soot build-up much longer, perhaps even the lifetime of your vehicle.
The Dynamic EGR feature has been in use for a year with no issues. It requires custom tuning price (about $50-100 more than standard). Other features are available with custom tuning: Dynamic idle control, left-foot brake fix, and glow plug duration & strength change.