I have a '93 300d - anyone know of a way or a kit to block off the egr valve? The engine is OM602.

Thanks!

Dave

I hate to use the word "search" Dave, but this is a long answer that GXSR and others have covered in detail.

From what I've read, the computer will not allow boost if there is a problem, and I believe that an in-op EGR will disable the turbo / boost. I might be wrong, a search on this forum and in the DIY section should turn up the appropriate discussions.

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Gone to the dark side

- Jeff

Not on the OM602. The computer controls the Turbo. If no EGR is detected it will disable the turbo. You have to swap to a pressure controlled turbo if you wish to disable the EGR on the OM602.
Attached is some reading on the EDS System on the OM602.962 system.
Sorry had to break it into to parts.
Hope it helps.

Attached Files

	1 to 11 OM602962EDSsystem.pdf (268.1 KB, 910 views)
	12 to 22 OM602962EDSsystem.pdf (267.7 KB, 184 views)

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92 300D 2.5L OM602 OBK #59

Thanks both of you for your quick replies! I have my reading cut out for me and will do that over the weekend. What actually are the advantages of deleting the egr?

Thanks again...

Dave

oh that is a feature which really sucks.

The EGR is for the reduction of emissions, but its sooty gasses combine with crankcase breather oil vapors to create a tar-like substance that slowly clogs the intake system like a BigMac in your arteries.

Supposedly fatal in some of the VW Tdi engines, so far only a performance issue in the 60x engines as far as I know.

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Gone to the dark side

- Jeff

I love my 603!! A tin shim and literally 5 minutes later, EGR is behind me forever. Sorry about your 93.

The PCV still sucks a fair amount of vapour juices, so black shows up in the intake, but a lot less. And I think some oil is getting sucked through the turbo bearings too... but, meh..

With all the pods and things taken off the car, the only thing left that the computer is controlling is electronic idle. Which is also kinda unnecessary, if I pull that, the car still idles at about 500 (my guess). I have freed pounds of useless stuff from that engine bay... to help it breath better and exhaust better. Greatly rewarded me in return with more pep under the pedal.

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Cheers!
Scott McPhee

1987 300D

I don't know about "fatal"... But, I have owned 2 VW TDI Passats. One 1996 (from new) and a 1997 (used). I pulled the 1996 intake after learning about the problem at over 100,000 miles. It was nearly 60 percent blocked! The dealers idea was to replace the manifold. At the time, I thought this ridiculous. If I had it to do over.... I would have replaced both of them.

On the second car, I bought the car with over 100,000 miles. I knew about the problem, applied the VagCom settings, disabled the EGR and removed/cleaned the manifold. On the 97 the manifold was nearly 80% blocked. The amount of air going through the intake was smaller than my pinky finger. STUNNING...... Stunning results after the cleaning too.

FYI.... Those 96-97 Passats were pretty big cars, 5 spd. and would fly like the wind. The only problem with them was slow steering and use of poor quality interior components (plastics). They handled well and would rarely get less than 41 MPG.

Bottom line.... Not sure what year TDI you are talking about. But most are pretty tough. It is unlikely that the clogging would have killed it. More than likely the engines computer would have helped it by providing less fuel based on the lack of air flow, blah, blah, blah......

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AJ

1985 300D (SOLD)

I'd heard that they could somehow lose a chunk into the intake and damage the valves/pistons or something like that, heresay at best.

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Gone to the dark side

- Jeff

When I changed one of my glow plugs I took off the intake crossover pipe. I cleaned it out. Yeap it was dirty. Just one of those things.

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92 300D 2.5L OM602 OBK #59

I have worked on literally "hundreds" of TDI's and have never even heard of that. Sounds like an isolated incident.

The only explanation would be an improper intake cleaning. Or fixing the EGR problem VIA the software and not cleaning the manifold after the fix. This would create a problem which "in theory" would allow the intake to dry out and "clean itself" over time. This may allow a "chunk" (as you describe) to pass through the engine. BUT, I can remember more than several people that did not want to pay for the cleaning and just opted to turn the system off. They never had a problem.

The process by which the crud accumulates takes lots of time and is like glue when it attaches to the manifold (in layers that are microscopic).

I would like to get my hands on one of those engines.... I am not "falling for it". Something else is to blame.

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AJ

1985 300D (SOLD)

BBDC,

I didn't realize they'd deleted the Vacuum Amplifier System on the '92 > .
I'll have to allow for it.

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'84 300SD sold
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