1.9 td EGR

[salutka]

Hi, I'm almost done with my MK2 conversion and I have a few questions about the EGR system on a 1997 1.9 TD (AAZ). I have tried to block off the EGR, by installing a plate between the valve and exhaust pipe (see attached picture), but the engine refuses to start with the plate in place. Also, none of the engine vacuum lines have been installed except for the brake booster. Does anyone have any info on the subject?

Thank you.
   

[burn_your_money]

Will it start with the plate removed?

Did you see this engine running?

Try putting 12v to the stop solenoid.

[salutka]

The moment I remove the plate the engine starts immediately. It still runs a little rough at idle but I'm guessing it's because the egr vacuum lines are not connected. Oh and there is a vacuum actuator behind the pump that I can't identify (not the one going to the turbo.)

[burn_your_money]

Try putting 12v from the battery to the stop solenoid and see if it will start with the plate in place.

Your air filter isn't completely plugged up is it?

[salutka]

No my air filter is brand new, and what is the stop solenoid? Is it the 12V line at the fuel pump?

[salutka]

Do you mean the wastegate hose?

Try pulling the hose between turbo and intake manifold and see if it starts then with the EGR plugged.

[burn_your_money]

Is it the 12V line at the fuel pump?

Yes. Not the one on the side of the pump though.

Try Andrew's suggestion first though if it's easier. I believe he means the boost hose that feeds the engine all it's air, not the small one going to the LDA

[salutka]

Ok thanks guys I'll try that out on Tuesday and keep you posted. One more thing, do you guys know where I can find the electrical diagram for the EGR system, I tried looking on mitchell but they don't seem to have it. If not I'll go see a VW shop.

[burn_your_money]

I would suspect the mk3 Bentley would cover it but I'm not sure. Maybe Vince knows.

[macka]

I would suspect the mk3 Bentley would cover it but I'm not sure. Maybe Vince knows.

yea I think it does, although my copy is at home

[Vincent Waldon]

Unfortunately the standard MK3 Bentley doesn't cover the EGR system very well... and the electrical part of it really really poorly imho.

There's a specific Bentley for the early Passats that supposedly does much better, but last I checked it was only available in electronic format for over 100 bucks.  

If you have specific questions we may be able to help you out... those of us graduates of the School Of Hard Knocks.   

[salutka]

Well I think I figured out the problem, the wastegate valve's internal shaft broke, now the wastegate is stuck closed, giving me 100% boost at all times.

[Rabbit on Roids]

that makes no sense as to why it wont start with the egr blocked. wastegate should have nothing to do with it. im wondering if the intake isnt plugged up?

[Henchman]

The moment I remove the plate the engine starts immediately. It still runs a little rough at idle but I'm guessing it's because the egr vacuum lines are not connected. Oh and there is a vacuum actuator behind the pump that I can't identify (not the one going to the turbo.)

That is probably for cruise control.

Unfortunately the standard MK3 Bentley doesn't cover the EGR system very well... and the electrical part of it really really poorly imho.

There's a specific Bentley for the early Passats that supposedly does much better, but last I checked it was only available in electronic format for over 100 bucks. 

If you have specific questions we may be able to help you out... those of us graduates of the School Of Hard Knocks.   

It's out there if you look for downlowad, not that I condone that!

Well I think I figured out the problem, the wastegate valve's internal shaft broke, now the wastegate is stuck closed, giving me 100% boost at all times.

This would only be an issue at high boost, idol you aren't making boost.  Did you pull the intake to see the level of cocking?  I've pulled somes and have been almost completely bloc ked

Hi, I'm almost done with my MK2 conversion and I have a few questions about the EGR system on a 1997 1.9 TD (AAZ). I have tried to block off the EGR, by installing a plate between the valve and exhaust pipe (see attached picture), but the engine refuses to start with the plate in place. Also, none of the engine vacuum lines have been installed except for the brake booster. Does anyone have any info on the subject?

Thank you.
   

Is this an actuall picture of your engine bayÉ

Ian

[salutka]

No it's not the the actual picture, just got one from google, anyways I got a newer jetta that's in alot better shape that i'll be using for my project. I'll be pulling out my AAZ soon and replacing the turbo with a new one. I'm going to wait this fall after school is over to start working on my project. Thank you so much for all your help, I'm gona post lots of picture's of my project during the build, see you this fall!