will dipping the intake manifold destroy the egr?

[BigJohneyK]

Auto value said that egr diaphrams are made of rubber so dipping it would destroy the egr.

How do you guys prevent frying your egr when you torch it and cook it and whatever you do?

 

[paramedick]

You don't fry/cook/dip 1Z/AHU intakes. You clean them by hand and pressure wash them.

A little citrus based degreaser helps.

 

[bluesmoker]

Auto value said that egr diaphrams are made of rubber so dipping it would destroy the egr.

How do you guys prevent frying your egr when you torch it and cook it and whatever you do?

this site explains everything
http://www.myturbodiesel.com/1000q/a3b4/clean-intake-manifold-tdi.htm

 

[BigJohneyK]

Right on, thanks bluesmoker. That sounds like trucker talk, haha...

 

[schultp]

I don't intend to hijack your thread but along these lines I have always wondered if someone has attempted to dismantle the EGR on the 1Z/AHU intake and see if there is a way to refurb a failed EGR. I know it is integral to the intake but obviously the components had to be installed initially.

This is more of a "I wonder if it could be done" type of inquiry. I realize the difficulties make it worthwhile to find an operational used intake instead.

 

[BigJohneyK]

i concur. If a guy can rebuild it, that would save what $400 atleast.

 

[BigJohneyK]

Then a guy could just dip it first.

 

[kooyajerms]

http://forums.tdiclub.com/showpost.php?p=1191906&postcount=44

not sure if it was successful though.

 

[schultp]

Thanks for the pic. This is from an MK4. Would the process be essentially the same to open the EGR on an MK3? Again, I'm not comtemplating doing this...just curious if it has been done successfully.

 

[BigJohneyK]

Im contemplating this! Haha....seriously, can it be done!?

 

[kooyajerms]

read.

 

[schultp]

read.

Unfortunately, the thread with the nice pic never had any f/u on whether this person was successful in refurbing the EGR. From viewing the pic I would worry about re-crimping the EGR cover properly.

One thing I wonder is whether the internal components from an MK4 EGR would fit in the MK3 EGR housing. If recrimping the cap could be proven successful then using MK4 internal parts could be a means for refurbing. Still costly if you had to buy a new MK4 EGR but maybe a used, working one could decrease cost.

 

[paramedick]

The poster was MOGolf and the rebuld was unsuccessful.

The Passat we just sold had the EGR dismantled and a bolt brazed into the shaft hole. If you have a tune with an EGR delete, that would work.

If you just want a factory intake with EGR functional, I have several non-leakers here. One for a 96 Passat, others with the bolt lugs for the EGR cooler.

 

[G60ING]

I'm working on a PD manifold with an AXR's EGR valve for my afn turbo upgrade. I'll be picking up the EGR pipe and EGR inlet flange tomorrow evening. The EGR valve cost me a little less than $120 from the VW dealer in Germany.

 

[BigJohneyK]

I'm working on a PD manifold with an AXR's EGR valve for my afn turbo upgrade. I'll be picking up the EGR pipe and EGR inlet flange tomorrow evening. The EGR valve cost me a little less than $120 from the VW dealer in Germany.

your speaking greek to me...

 

[shin]

when the egr opens does it shove all the boost into the exhaust?

 

[G60ING]

your speaking greek to me...

The passat PD manifold is an upgrade option that some of us use on our 1Z and AHU tdi engines found in the mk3 jettas and b4 passats.

I've found an EGR valve that will bolt up to the manifold that doesn't have the mk4 shut down flap. To top it off the egr valve is half the price of most mk4 egr valves. Here is a picture of installed on my turbo upgrade:

 

[schultp]

G60ING, I wasn't aware of this option. While I don't need to replace my intake thanks for sharing this info.

 

[BigJohneyK]

so just to clarify because I haven't had my cup of joe yet

You replace the stock I.M. with that IM pictured above, then you can get a different egr that you can replace whenever because it is separate.

Am I on the same page?

 

[G60ING]

correct. Now I did have to weld that EGR pipe together to make it work. Under that stainless steel woven band is a weld.

 

[BigJohneyK]

"New intake manifold/EGR setup"

You knew this question was going to come...

How much is this modification?

 

[G60ING]

I bought the Intake manifold from ebay.co.uk for $20 and shipped it for $50. The EGR valve was $130 shipped with a few bucks for my friend included in that. and then I welded up the old ahu egr cooler pipes for $25 in welding fees. Then there is the flange portion that a friend is making for me.

 

[BigJohneyK]

$225 not bad in comparison to $450+

 

[TeeCee]

I am trying to duplicate this setup sans AFN & the turbo
Just to replace the ahu manifold & EGR
Is it possible to get the part number of the
PD130 manifold that is used
confirm AXR's EGR valve(038 131 501 AN) ??
Also what are the details of the flange I dont have fab skils but I assume
I can take to a machine shop if i know what i am adpating

 

[G60ING]

This thread looks like it was one that I used way back when for info:
http://forums.tdiclub.com/showthread.php?t=248917

 

[G60ING]

I just took a look and it looks like I have the AJ manifold. As for the flange I can't help you there. I know my Fabrication guy just took the EGR valve and then made a flange, he is good like that but I try not to impose a lot of special requests on him.

 

[lisab4]

Get a European B4 TDI manifold. The EGR valve is a simple bolt-on affair. Easy to clean, and if you want to delete the EGR, you only need a blanking plate.

 

[TeeCee]

I just took a look and it looks like I have the AJ manifold. As for the flange I can't help you there. I know my Fabrication guy just took the EGR valve and then made a flange, he is good like that but I try not to impose a lot of special requests on him.

G60 did this 038 131 501 AN egr require an ecu egr delete or does it match
the same pressure so that no 1403 code is tossed
UPDATE egr delete was NOT required

do you know if that bolt pattern on AG manifold is the same as the AJ so that the AN egr will bolt up
There are tons of AG manifolds on ebay de or uk aj is a harder find
http://www.ebay.de/sch/i.html?_from...0.l1313.TR0.TRC0.H0&_nkw=038129713AG&_sacat=0
UPDATE AN EGR Bolts up but did require ovaling 1 bolt hole in the egr flange

Also did you look at this egr pipe 028131521AD
http://www.piesedindezmembrari.ro/imagini/71592924-72979417-20825722.jpg
UPDATE I made a custom pipe as well


UPDATE
I also retained the EGR cooler & had to weld a boss to the PD130 manifold to allow the AHU EGR cooler to attach

see this thread for some observations
http://forums.tdiclub.com/showthread.php?p=4696410#post4696410

 

[G60ING]

The tune I have for my EGR is for a dynamic EGR tune from Malone. It doesn't throw any codes.

I have no idea about the intake manifold bolt patterns.

I don't know about that EGR pipe, I want to say that I probably had that in my bin or spare EGR pipes when I started. I bet that the clocking of the flanges is wrong.

 

[TeeCee]

G60ING
I am curious I ended up getting a 038129713AG manifold and 038131501AN EGR
1 bolt hole on the manifold side of the EGR valve do not line up out maybe 1mm
I can probably make it work ovaling/slotting but did yours bolt straight up
to the 038129713AJ manifold or did your machinist maybe make the adaption to the manifold when he created flange adapter ?