AAZ EGR Please school me.

[haybayian]

I am working from a VW AAZ long block and I don't have the priviledge of having seen a 1996 jetta TD engine complete nor to have one handy.

I would be grateful if someone familiar with the AAZ could guide me a bit while I try to put the EGR system together. I have Bentley and Haynes and this area still reads like Greek to me. For instance how does one understand " Control of the EGR system is through the Automatic Glow Time Control Module (J179) by way of input from the EGR Part Throttle Switch (F166) in the injection pump..." what are these?

What I need is the idiot's guide to those things. Thanks for your help.

Haybayian

[QuickTD]

The EGR part throttle switch is located on the top of the injection pump and is actuated by the throttle linkage at low throttle settings. This switch is used in conjunction with the glow time control module to actuate the EGR valve and wastegate change over valve at certain conditions of speed and load. Here is where it gets a little strange... The wastegate change over valve controls vacuum to the wastegate actuator, the wastegate actuator pulls the wastegate open during EGR operation to prevent the turbocharger from making boost and to create stable pressure conditions in the exhaust and intake manifolds. This setup is present on the jetta as well as the passat. Only the passat has an actual EGR valve installed on the intake manifold elbow. For reasons known only to VW, the jetta does not have an EGR valve, nor does it have the necessary flange on the intake elbow or the exhaust manifold to mount one. This makes the rest of the system useless, it serves only to decrease boost response by holding the wastegate open at low rpm. I would remove all the parts associated with the EGR system and toss them. The glow time control module will operate properly without any of the EGR junk.

[bert]

To be honest the best thing to do is to remove the whole egr system,it causes more problems than good,it will eventually block the inlet manifold with carbon and soot,this mixed with recirculated oil vapour makes a nice sticky goo
Bert

[haybayian]

Thanks Quick TD and Bert,
As much as I like your suggestion to ditch the EGR I don't think that I can do it.
Here in Ontario the process of registering a kit car powered by a 1.9 L  TD VW diesel will include a MTO inspection. It is not clear to me how this inspection will be concerned with the nuts and bolts of  my car's plumbing, but on paper they should. So not to take chances I will leave the EGR bolted to the manifold (my manif has a spot for it) and I will try to make it work from the Glow timer unit input,  leaving the wastegate alone....if it all makes any sense.

Quick TD could you show me were the (said) switch is on the top of the IP?

Thanks again guys.
Haybayian

[bert]

OR just blank the pipe off with a bit of steel shim,they will think it still has egr but you know better  :wink:
Bert

[jtanguay]

Thanks Quick TD and Bert,
As much as I like your suggestion to ditch the EGR I don't think that I can do it.
Here in Ontario the process of registering a kit car powered by a 1.9 L  TD VW diesel will include a MTO inspection. It is not clear to me how this inspection will be concerned with the nuts and bolts of  my car's plumbing, but on paper they should. So not to take chances I will leave the EGR bolted to the manifold (my manif has a spot for it) and I will try to make it work from the Glow timer unit input,  leaving the wastegate alone....if it all makes any sense.

Quick TD could you show me were the (said) switch is on the top of the IP?

Thanks again guys.
Haybayian

its Ontario man... they'll only do the visual soot inspection.  they might check for exhaust issues/leaks but thats it, oh and maybe the presence of a CAT if the car had one previously.

[dillenger1]

Bond..... James Bond
so i was wondering about the waste gate actuator and the egr.Is that the reason why you cant build any boost without load on the engine?Because that seems kind of confusing to me.(reving engine with no boost being built)The turbos sounds like its compressing,but still its not

[foxracer1]

Free reving doesn't produce enough of a load for a turbo to have time to build boost. Some smaller turbos might. The engine must build heat. Heat is the bigger factor to making a turbo spool not exhaust flow like most think.

But i'm not fimilar with the EGR setup from what it sounds like it may also limit low load boost for emission reasons.

[haybayian]

its Ontario man... they'll only do the visual soot inspection.  they might check for exhaust issues/leaks but thats it, oh and maybe the presence of a CAT if the car had one previously.[/quote]


Thanks Guys,
I have already ordered a brand new cat and EGR and the cost broke my heart. Could someone tell me how to wire the things so that I could put it all behind me.

Haybayian

[QuickTD]

The first pic in this thread shows the part throttle switch,

http://vwdiesel.net/phpBB/viewtopic.php?t=579&start=0&postdays=0&postorder=asc&highlight=

I'm with the others, they do not check emissions on a diesel car in ontario. They'll only check to see if the exhaust system is visibly intact. I wouldn't worry about the EGR. If you actually have an EGR equipped engine then just ditch the EGR parts and get non-egr stuff from a jetta/golf 1.9 or use 1.6 parts. I can probably hook you up if need be. I would never even consider hooking up the EGR, it kills engines.

[haybayian]

The first pic in this thread shows the part throttle switch,

http://vwdiesel.net/phpBB/viewtopic.php?t=579&start=0&postdays=0&postorder=asc&highlight=

I'm with the others, they do not check emissions on a diesel car in ontario. They'll only check to see if the exhaust system is visibly intact. I wouldn't worry about the EGR. If you actually have an EGR equipped engine then just ditch the EGR parts and get non-egr stuff from a jetta/golf 1.9 or use 1.6 parts. I can probably hook you up if need be. I would never even consider hooking up the EGR, it kills engines.

Thanks again QuickTD,
I have saved the quebec file for future reference. I think that I will consider the advice that you and others on this forum are giving me: ditch the EGR. I will keep the cat so that appearences will be saved.

Whereby to you live? I am in Napanee. I may take you up on your offer to help with my hook ups some day. My kit car will hopefully hit the road this Spring.

Take care.

[jtanguay]

good luck with the car!  just remember that EGR system is one more thing to make your car run like crap.  if the EGR valve sticks open your car will idle like crap when hot, and might cause damage under boosting.  of course if you drive like a madman and keep those egt's up it might be enough to keep the valve clean  :wink:

i would even say just hollow out the cat.  if that thing plugs you're also screwed... the backpressure can do horrible things...  not sure on a diesel, but on a gasser if a piece breaks away and plugs the exhaust while you're on the highway, bye bye valves  :shock:

[jimfoo]

A plugged exhaust will send EGT's through the roof.

[QuickTD]

Thanks again QuickTD,
I have saved the quebec file for future reference. I think that I will consider the advice that you and others on this forum are giving me: ditch the EGR. I will keep the cat so that appearences will be saved.

Whereby to you live? I am in Napanee. I may take you up on your offer to help with my hook ups some day. My kit car will hopefully hit the road this Spring.

Take care.

What I meant was I can hook you up with a non-EGR parts if needed. I'm quite a long way from napanee, 5-6 hours drive I would think. I'm on the "west coast" of ontario, north of London, close to Grand bend. If you want to make the trek, I can certainly help you out!