EGR block off/Double relay query

[al_kaholik]

Scott, which of the plates would fit a beetle then, presumably just the single one, but I'd need a couple of those and once we get talking about shipping the price rockets

[al_kaholik]

After a Heath Robinson moment I've blocked the valve side of the EGR using some of the can of a very well known diet fizzy drink. Now it's raining after weeks of sunshine and I'm out doing the car!

Anyhow after a quick test drive the engine feels a lot cooler where it would have been hot as an oven before. Next step will be on the weekend blocking off the exhaust end as I know there is a big hole inbetween there and where it comes into the engine bay, then getting some sheet metal cut to the template I made. 1mm plate should be fine right?

Someone was nice enough to drop a business card for a local air cooled specialist on my windscreen while I was on holiday and I picked it up and gave them a ring. Turns out the owner was well chuffed when he saw the car as he used to live in Japan and knows a little (though possibly a bit less than me now) about the FI and A/C system its running. He's coming around on Sunday to check out whether they are able to tune the car and it'll go to their workshop for a very reasonable price if they can. Result.

One FI bug getting back to running smoothly :D Probably going to take some leave from work to get home and have a look at the double relay in a few weeks time.

Thanks for your help Dick.

Al

[dtrumbo]

You're very welcome. As I understand it, blocking off that leaky EGR will prevent an overly lean condition which is why your engine is cooler and therefore happier.

Glad you're on the road!

Cheers!

[al_kaholik]

And after a look tonight at sorting the block off at the elbow, it turns out that the pipe is basically falling to pieces where it comes off the muffler! the nuts and bolts are rusted up so its a grinder job

i'll be getting a pre-heater block off and some new nuts and castrating it on the weekend!

One thing always leads to another...

[dtrumbo]

Mine was rusted out there as well. I ordered up a new muffler (Ansa) so I could restore my EGR system. The sound the muffler makes is HORRIBLE! I absolutely hate it, but at least I have a complete EGR system!

[al_kaholik]

Muffler is £150 for the non-cali spec. So very expensive for a tube of metal!

Like I said it's going to be blocked as it isn't required in the UK on a car of the age. I'll look to reinstating the whole system in the future, possibly after getting a non-cali muffler made - it'll be a lot cheaper and i can have it as I'd like.

So onto the next question, IF I were to remove the cat and replace with a non-cali style muffler what goes on with the Lambda probe and how would this affect the ECU and running? Would it be best to stick a thread in a similar position to now and run with the sensor? Because presumably if it senses nothing it'll run either very rich or very lean.

:)

[Amskeptic]

IF I were to remove the cat and replace with a non-cali style muffler what goes on with the Lambda probe and how would this affect the ECU and running? Would it be best to stick a thread in a similar position to now and run with the sensor? Because presumably if it senses nothing it'll run either very rich or very lean.

It will default rich-ish, the way we like it. At that point, you can adjust the AFM to your liking without some Lamba-probe telling you otherwise.
Colin

[al_kaholik]

Pipe is now blocked, but the exhaust is definately blowing froms probably everywhere now.

So all will be good without the cat, adjustments are then made on the AFM adn we do away with all the expensive bits and pieces?

I'm probably going to get a stainless replica made of the what is there, but substituting the cat etc. for just a can with all the outputs in the correct places. Is this the best idea? there are loads of places that will knock things up cheap like that over here

[BellePlaine]

we make an EGR blockoff kit:

http://www.germansupply.com/xcart/custo ... ctid=17780

Now that is cool. This kit is going on my list.

[al_kaholik]

Cut up tin cans do the same job ;)

After investigating the options at present, I'm looking into getting a standard non-cali muffler though I will be pressing the company to sell it me cheaper than they have advertised.

That way I can get the whole setup off and replicated, cross pipe and the back box, potentially with a cat too less the EGR take off.

[al_kaholik]

Its arrived...

http://carben.co.uk/pix/main.php?g2_vie ... alNumber=2

along with some other parts. Not sure on the make at present cause its a pic from the old man, can't be worse than whats on it.

To be installed in a couple of weeks. Going to block the EGR as planned with some 1 or 2mm plate that I have at home when I sort it all out.

The car is going in for a valve job and general service before I put the exhaust on and tune it on the AFM.

Should I just disconnect the lambda from the furthest location back? Need to find out exactly where it goes then box it up for later...

[Amskeptic]

The car is going in for a valve job and general service before I put the exhaust on and tune it on the AFM.

Should I just disconnect the lambda from the furthest location back?

Valve job? as in "adjustment" or "heads-off re-grind" ?

Lamba from furthest location back? (sensor? location back as in back bumper back?)

Colin

[al_kaholik]

Adjustment! As mentioned earlier in the thread the place I have to work is unforgiving at best at the moment.

The boys at the garage are doing a few other nasties that I can/have done before but its easier to get them to do it. The owner's wife is from Japan and they have loads of contacts out there from when he used to work at a garage there. If you get a chance to look in a Flat4 catalogue there are plenty of interesting parts to be had. NOS Judson engines for sale - impressive.

And sensor furthest back from the actual probe, presumably theres a connector somewhere along the lead?

[al_kaholik]

So the new exhaust is on, little disappointed as the new tail pipe doesn't fit so will need to get one from elsewhere. Probably one of the bolt on ones from Halfords - nice and boy racer...

Anyhow, everything is pretty good but the backbox is peppered and needs either replacing (with stainless) or plating. I'll be getting one done out of stainles an getting everything back to stock. At least its on the road at the moment, which it wouldn't be if I hadn't bought the new one.

Pictures - new and old


Heat exchangers for reference



Non fit of the tail pipe and fitting kit





Cheers for all the help and good motoring at the moment - I believe that the AFM is "upside down" so adjusments while running the engine may be a little tricky, but I'll have a look at some point.

Al

[dtrumbo]

Congrats on the exhaust! I didn't quite get from the picture why the tailpipe doesn't fit. Is the pipe too small to fit over the outlet pipe (technically the tailpipe) of the muffler? It looks like the gasket fit o.k. I'm sure you'll get it figured out one way or another.

I believe that the AFM is "upside down" so adjusments while running the engine may be a little tricky, but I'll have a look at some point.

Yes it is, which is why I haven't checked my mixture (other than plug-reading) yet either. I've seen photos of engines that have the AFM rotated to be "right-side-up" with the wire harness re-routed. As I recall, the author of the photo said you can't drive it that way due to clearance issues with the engine cover, but it does make it a lot easier to adjust.

Glad you're on the road!