Today I.....

.....started EGR modification for my TDI 75. As it is combined unit with anti shudder valve,
I removed the EGR membrane and inner workings in order to get better air flow. Now it's
On to the machine shop to remove the steel seat for the valve and close the two holes
that valve was in.

See the photos

IMG_2074.JPGIMG_2075.JPGIMG_2076.JPG

It's still rough, but its work in progress.

Regards,
Boris
 
Today i finally cured my beastys limp mode , I replaced all the vacumme hoses and added mini gubilee clips to all the main connections plus removed all the boost hoses and gave them a good scrub inside and out as well as flushing out the intercooler... after a test run and no limp mode i swapped out the standard ECU for my modified one and smile time is hear again which is well needed after yesterdays purchase from TPS , im sure AUDI think up a price double it and trebble it a few times LOL .... the tiny oil fill up corrugated pipe had become brittal and started weaping oil , so thought best to replace before it goes all together and emptys oil everywhere £112 later and a big OMG but had to be done as my temp fix of insulating tape wont last in the long run..

IMG_2423.jpgIMG_2426.jpg
 
£80+vat for a small plastic tube with a metal bit? Gary you of all people could have made one out what you had laying around



Sarge
 
yes i could of made something up but could not risk it failing at some point in the future as could be an engine killer if i was say on a motorway at a fair rate of knots when it let go and after the many hundreads of hours ive spent building my engine i want it to be 100% and not skip on something like this ...
 
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67boris said:
.....started EGR modification for my TDI 75. As it is combined unit with anti shudder valve,
I removed the EGR membrane and inner workings in order to get better air flow. Now it's
On to the machine shop to remove the steel seat for the valve and close the two holes
that valve was in.

See the photos

View attachment 30323View attachment 30324View attachment 30325

It's still rough, but its work in progress.

Regards,
Boris
Click to expand...

I used my air die grinder to notch into the seat on opposite sides and it just falls out ... then some magic with a tig welder to weld both the holes up and you can shape it out to your hearts content ..
ive some photos somewhere if i can find them.

IMG_2429.JPGIMG_2431.jpgIMG_2432.JPG

The only part that was a nightmear was the butterfly for the shut off is not removable so makes work awkward and final tweaking took time for a good seal when closed after opening out all the insides for better flow
 
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Thanks JIGSAW,
I'll have a go at the valve seat, but I'm short of TIG welder, so it'll end up in a local shop anyway. Once welded up, all excess material will be removed to save weight lol.

Regards,
Boris
 
67boris said:
Thanks JIGSAW,
I'll have a go at the valve seat, but I'm short of TIG welder, so it'll end up in a local shop anyway. Once welded up, all excess material will be removed to save weight lol.

Regards,
Boris
Click to expand...

Nhahahahahahaha got save them grams laughing my socks off , make sure they weld it right to the outside edges, diameters as you can carve loads of alloy from the insides especially the side that bolts up to the egr corrugated pipe as has a huge step on the inside and all that can be removed to open it right up

boris IMG_2076.JPG

you can see in the photo ive taken a fair bit of it off already and opens the port up a treat
 
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Wow, that's big port. Thanks for the tip,
I'll make sure they do it right. How big was the difference in driving?
 
67boris said:
Wow, that's big port. Thanks for the tip,
I'll make sure they do it right. How big was the difference in driving?
Click to expand...

Oh its scary quick now and trys to pull the tyres off in first and second but not right yet , still loads to do before i go visit a rolling road as still running standard injectors and rear system at the moment and got some pd150 injectors and a stainless exhaust system to make and then theres a fmic to gain the best cooling of the charge air as the standard ones location does hinder this and then get her set up right on a rolling road and release all her horses.
 
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Hi Spike,
I read Tom's post the same day, it's a piece of art what you did, but no access to a lathe for me.
My idea was to fill both holes completely and then machine the inside to
achieve a smooth path for the charge air.

You don't happen to have another one of those blanking plugs lying around, do you?

Thanks,
Boris
 
Plenty of A2's in Norwich

Took the TT on a road trip to Norwich, seen 3 A2's already so a good show from the camp.
95 faultless miles and 37.5 mpg, not bad for a 3.2, so I'll take that!
Sorted some quality Audi parking too alongside a nice S3,
Looking forward to a trip on the river tomorrow!
Cheers Jeff
 

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Looks fab - get ready for "can you fit me one" it really makes the dash more modern looking and with increased functionality.
 
craigyb said:
Get ready for no way, it's far too scarey a risk to take on someone else's cluster if you break it.
Click to expand...


That is why I gave my new colour screen to Tom to fit (when he gest a slot in his busy schedule!)

I don't "do" electrickery !!!

They are pretty amazing.

Steve B
 
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