When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
So what is all this stuff under the intake manifold that gets in the way of servicing your engine and turns a 1 hour project into a 5 hour project its an ( EGR cooler ). So anyone who is building an offroad / track cars here is the information you need about doing the Hardware delete and cleaning up the engine bay for easier access to everything including from (hearsay: what im reading is if you want to upgrade from a CP4 to the more reliable CP3 pump this has to be removed to allow for clearance.
So items you will need...
(a hot-side block off plate for the turbo housing, I could not find any available with a straight forward "yes it fits" so I ended up having a machine shop make me one, I brought them the metal gasket and told them to make a metal block off plate to the dimensions of the gasket, car sat for 2-3 weeks waiting for the part)
(a cold side block off plate for the intake piping, I could not find any available with straight forward "yes it fits" so I am having another one made, I pulled the thing out that protrudes into the intake pipe and had them make a block off plate to the same specifications as the flange size
)
(a water connection to connect from this to this, i have cut of the portion of the egr cooler that slide over and bolts onto the one further away and I had it threaded to accept a NPT barbed fitting to connect the existing waterline to a 3/4" hose pipe connection)
Vacuum im not sure yet on what is require or what each one of the removed sensors does so I will add more information later, there is definitely 1 vacuum line that needs to plugged , but quite possibly more can be eliminated.
Last edited by Rollerlocked; 02-16-2021 at 07:21 PM.
Updated first post with more pictures, Also I figured out that the water temperature sensor in the EGR is required, otherwise your dash temperature gauge doesn’t work, and even though it suppose to fail safe to the 2 backup sensors it doesnt and it throws a p0118 with the sensor disconnected. With the sensor connected but not in a water stream it throws , P0116, p0128 cel.
Also I’m testing if any of the other sensors on the egr can be deleted and the vacuum lines can be cleaned up by unplugged one at a time.
So far the following 2 sensors circled in red are safe to remove with no ill effect, the sensor circled in green is required.
The change over valve circled in red below can be disconnect... disconnect the vacuum line from the vacuum on top of the egr cooler and reroute the vacuum , the sensor can also be unplugged and removed.
next items that are going to be tested are the butterfly valve. (if this can be deleted ill work with the machine shop on making a replacement housing that doesn't contain the butterfly valve in the intake tract or the electronics hanging off the side.
and the coolant shutoff valve which is connected to this solenoid, I wonder about making a thermostat housing that accepts a standard thermostat and eliminates all the vacuum lines and the common coolant leak point, from what I can tell this is some overly controlled and monitored thermostat housing.
RLHornBeck if thinking about doing any of this please keep in mind you will need the Malone tuning software delete of the EGR and DPF for (offroad use only.) I am current tuned to stage ? as I have a few modifications done.
Last edited by Rollerlocked; 02-16-2021 at 08:26 PM.
assyrianme, it not from a pdf, its from an online source that requires a membership and there is no way to just download all of the images or instructions, you have to browse thru each thing till you find what your looking for then you can print to pdf a specific section, if its something in particular you are looking for I can see if I can find it on there. I wish I had a Factory service manual for this car.
Also I was browsing on another forum and stumbled into a post where someone else is custom building the EGR physical delete stuff to allow for room for a CP3, they took it a step further and I think I may end up having to go that step further for the CP3 fitment. Heres some pictures I grabbed from the other forum.
Last edited by Rollerlocked; 02-21-2021 at 07:12 PM.
Well the machine shop I was working with is getting some new machines installed so the part was kind of hand made by one of the technicians there, and I installed it today.
@Rollerlocked Old thread but I thought I would post. I have a 2013 Cayenne diesel. My EGR completely failed. It sent coolant into the intake hose. Porsche wanted $1400 just for the EGR. My buddy who is a mechanic said to remove it since I have a stage 2 Malone tune. He had 3 parts manufactured that cost $250 inc taxes. Two block off plates. One is made in steel for the turbo. One in aluminum for the intake. Then the sensor adapter. He bought the Gates 28475 hose and a few hose clamps. Was a lot cheaper. He cut the corner off the EGR cooler so it would connect to the flange like you did. He had two codes when he started it. $0E78 and $0E79. Probably had to do with removing the fuel line from the rail. Cleared the code and drove 50kms. Codes never came back. The only thing I still am questioning is there is a vacuum line that connects to the EGR. He just capped it off. What did you do with yours?
So my mechanic just capped off the vacuum line. Had 3 engine codes all EGR related. Malone sent me two new codes. One for the EGR delete and one for a complete delete should I remove my DPF. All the codes are gone and it's running perfectly.
Just curious: Is there enough interest in EGR removal in the CD crowd to encourage a vendor/member to come up with a quick repeatable solution? I know I'd be interested. All it would really take would be fabricating a small bulk run of all the bits and pieces at the same time as creating one's own solution [ something like this: https://www.atmspeedshop.com/collect...-block-off-kit or if you want to get a bit fancier, this https://www.tunemyeuro.com/eco-bille...5-35d-aar2353/ ].
I'm at least 3-6 months away from having the time to fiddle with my much-better-half's new (to her) CD, but this is definitely one of the first more major items on the list given the havoc that these systems tend to wreak on intake air systems/manifolds (not to mention potential for coolant leaks which--if these TDIs are anything like other drivetrains--tend to be made higher likelihood when digital/physical block-off is performed without a complete removal of the EGR cooler).
So nobody in the business has created an EGR delete kit yet? Kudos to the OP for taking the bull by the horns and doing this yourself. Do you want to make kits and sell them here? I’d be #1 on your list.
So nobody in the business has created an EGR delete kit yet? Kudos to the OP for taking the bull by the horns and doing this yourself. Do you want to make kits and sell them here? I’d be #1 on your list.
I would be No'2 on your list as my 2011 is throwing the P04011 code as well.
I have a local tuner that uses the Malone that will do a stage 1 and EGR/ DPF delete...so I have that covered.
I would like to lose the DPF and install the straight thru pipe. No affiliation with Darkside just posting links for info to help push the development along
02-07-2021, 05:41 PM
2013 Cayenne diesel CD 958 EGR physical delete
