TDI inlet manifold and EGR question.

[thai-wronghorse]

Ive been looking at upgrading the inlet manifold on my AHU seeing as its due to come off for a damn good clean up and service anyway. Ive read that the PD130 inlet is a direct fit and a better design. Using this will also allow the complete removal of the wretched EGR valve.If I remove all the associated parts will I need to have the EGR mapped out of the ECU or does this only apply to later TDI's...eg PD engines? I don't want to ditch it all and be left with a mass of fault codes and/or the engine stuck in limp mode.

[xionsolaris]

I don't think that diesel engine has limp mode i could only search and find this. This suggests that you don't need to map it out of the ecu. Is the egr valve electronically controlled. Correct me if I am wrong I am guessing from the age of the mk3 golf it will be a diaphragm egr valve. Just had a look at some images and it appears to be a diaphragm egr valve the ecu will not be monitoring this.


Self-diagnosis
Features of self-diagnosis
The control unit for the Diesel direct injection system is equipped with a fault memory.

If faults occur in the sensors and components being monitored, they will be stored in the fault memory together with an indication of the type of fault.

Faults which only occur sporadically will have the addendum "sporadic fault" on the print out. These faults will be indicated on the display by the addendum "/SP". The cause of sporadic faults can be e.g. a loose contact or a brief open circuit. If a sporadic fault does not occur again within 50 engine starts, it will be erased from the fault memory.

If faults are recognized, that affect the driving condition then the glow period warning lamp flashes.

The faults stored can be read-out with the fault reader V.A.G 1551 or the vehicle system tester V.A.G 1552 => Page 01-7 .

The fault memory must be erased after the faults has been eliminated => Page 01-35 .

Note:

General information for self-diagnosis is in the fault reader V.A.G 1551 and the vehicle system tester V.A.G 1552 instruction manuals.


The codes that SHOULD make the glow plug light flash are

00513 Engine speed sender -G28
00542 Needle lift sender -G80
00626 Glow period warning lamp -K29 - Short to earth (glow plug light permanently on)
00741 Brake pedal monitoring
00765 Modulating piston movement sender -G149
00777 Accelerator position sender -G79
01268 Metering adjuster -N146

[thai-wronghorse]

Thanks for the in depth reply....although a lot of that has gone right over my head as im new to diesel tweaking.

Im pretty sure they do go into limp mode as my last AHU TDI would occasionally due to a vacuum fault somewhere which then feel like the car had no turbo but would be fine after turning the engine off and back on again...untill you put it under heavy load.


Ive started a thread over on Facebook with pictures which might make things a little cleare for anyone reading.

https://m.facebook.com/home.php?refsrc=http%3A%2F%2Fm.facebook.com%2Fhome.php&refid=8&_rdr#!/groups/492170747463631?view=permalink&id=798432983504071&notif_t=group_comment&ref=m_notif&__user=610950692

[Len]

Cant remember what was on the diesel engine I bought but there maybe an inlet manifold. TDi engine

[benjy_b]

Passat PD130 Manifold
EGR valve delete (for Passat)
Silicone Hose to connect

No fault codes when removing EGR on MK3 Golf :-)

[thai-wronghorse]

Perfect thats what I had in mind. Ive found one from an AWX  engine for a really good price so il get that then. 

Another quick question, what is little sensor / solenoid /box thing located on the drivers side suspension turret?

[benjy_b]

There are two valves in that area;

N75 (Boost Solenoid) - Metal valve with red, blue and black hoses, controls wastegate on turbo with boost pressure

N18 (EGR Solevoid) - Black plastic with black hoses, controls EGR valve with vacuum

You can unplug and remove the N18 valve, don't touch the N75. Make sure you plug the vacuum hose to the N18. If you trace it back, you can plug it at the distribution fitting near the top of the gearbox.

[thai-wronghorse]

Ah right, I thought those solenoids were the other way round...I  that case should my N75 (the one with red, blue & black hoses) sound like a typewriter as it bloody irritating?

[benjy_b]

You shouldn't be able to hear it over the engine noise.

The only time is cycles without the engine running is when you do a test in VCDS.

Are you sure it's not your glow plug relay clicking?

When does the sound occur? All the time, when ignition is on, when engine is running?

[thai-wronghorse]

The clicks / tapping are constant when the engine is running.