EGR Cooler delete ARL engine

[ArmzFR150]

Hi guys as some of you may have read the head is currently off my Leon FR 1.9PD150 ARL engine due to the injectors wearing the head away causing the injector seals to fail.

I already have the EGR deleted completely from straight off the turbo and a Allard delete pipe with SFS boost hoses however while its all off i want to remove the EGR cooler as well.

I did do a search but couldnt find what i was after.

It would appear that you can bypass the main coolant in and out pipes by joining the input straight to the heater matrix and doing away with the output pipe from the cooler to the matrix.

However on the 150 engine theres a small return pipe out the top of the cooler that runs back to the expansion bottle so what to do about that?

Had a look at a few ASZ 130bhp engines and BXE 105bhp engines and neither of them have this return pipe so can i just forget about it and remove the T piece on the expansion bottle output?

/having just bolted down the new head and gasket etc as well as new turbo and spent owell ver a grand in parts on the car i dont want to stop the coolant circuit flowing correctly or let it get hot spots etc.

Have many people done this mod?

 

[leegreenaway]

I think i just blocked that return pipe on the expansion bottle, like you said it's a return pipe.

As for the water pipes in/out you can either replace them with one long piece of 19mm IIRC pipe or bridge them with a 19mm straight connector. I just bridged them and had no issues.

As for the delete, just make sure you get the EGR mapped out of the system

Used to an ARL engine on my MK4 Golf GT TDi, apart from being an expensive b*tch on parts it was good until it blew up lol

 

[anni25pd]

As said above have always used an inline connector for the water pipes without issue & lose the return pipe as the cooler is no longer there. From memory you can use existing pipework just route it in a different way.
Will get you a snap of my 150arl set-up 2moro night when back at garage

 

[ArmzFR150]

Cars already running a "blacksmoke" 182bhp remap with EGR turned off. Just still had the cooler there. Now I've removed the head and turbo seems stupid bolting that back on.

Think I've got a spare joiner somewhere in my toolbox at work so will either do that or swap the pipes around.

It looks like there should be enough length using the longer of the 2 original pipes to go straight to the matrix but I Havnt bolted the water housing back to the side of the head yet so it's hard to tell.

 

[leegreenaway]

My engine blew with the black smoke map, they're just so generic. Hence why I'd rather get it done properly these days

 

[ArmzFR150]

Lol really? I've had it on there for 5 months. My mate who has a fabia VRS is just getting into custom mapping his own cars. He's mapped every diesel I've ever had but only with generic maps but now he has software to create and alter your own maps.

We looked a the blacksmoke one and it only adds 0.2bar of boost an slightly raises te fueling to compensate. Definitely goes better and doesn't chuck out black smoke.

However I think if anything it's on the lean side so I may get him to up the fueling slightly more.

With the head off I Havnt seen any signs of the pistons or valves getting damaged at all so think mine is ok on it.

My turbo has been massively overboosting as well going over 2Bar at times .

Oil seal is failing on the exhaust side since I mr muscle cleaned it so just putting a recon one on at the same time as the head.

 

[leegreenaway]

After my turbo went it got worse lol, i blew up 2 injectors and it started p*sssing fuel into the cylinders....it wasn't fun. Being an ARL code it was a b@stard to get parts for and any I did find were stupidly expensive

So sold and bought my 1.8T instead.....never going back lol

 

[BenG]

OP, is this part any use for bypassing the EGR cooler?

http://www.darksidedevelopments.co.uk/products/1-9-8v-tdi-pd150-arl-and-us-alh-bew-pd100-egr-cooler-delete-pipe.html

 

[leegreenaway]

Yep! Good find!....or a £2 19mm straight connector lol

 

[anni25pd]

As promised 1st pic shows additional pipework removed from near header tank & remaining pipework routed slightly differently(no cutting)

2nd one shows coolant pipes connected with inline 19mm connector (hopefully)

Hard to get pipes in focus due to tip..... Plz bear in mind this on my anni golf mk4 with arl lump but should be same as your Leon

 

[ArmzFR150]

Brilliant job, yup that's pretty much exactly what I've done today.

Removed the t piece from the return pipes to the bottle and used the longest hose out of the 3 to go from The bottle to the rail at the front of the engine.

Ordered a 19mm barbed nylon joiner for the other pipes. I plan to use the original pipe from the thermostat housing and a 90 degree bend cut off the other pipe joined together to meet the heater matrix.

Got on well with putting the engine back together after work today.

May well get it running tomorrow if I get time.
Got a bloody vauxhall engine to strip tomorrow so see if I feel like cracking on with the Leon after that or if I've had enough of engines lol.

 

[ArmzFR150]

After my turbo went it got worse lol, i blew up 2 injectors and it started p*sssing fuel into the cylinders....it wasn't fun. Being an ARL code it was a b@stard to get parts for and any I did find were stupidly expensive

So sold and bought my 1.8T instead.....never going back lol

The bosch injectors are reliable as anything so every diesel specialist or vag specialist tells me.... but about £1500 a set if they do go wrong!

The problem with mine was the injectors had warn away at the head meaning the injector seals failed and neat diesel was running into the cylinders. could be what was up with yours but mine still shows spot on readings for idle stabilization on vagcom. (while it was chucking out white smoke on idle)


Also yeh that cooler delete pipe on darkside will do the trick nicely but can easily do the same thing with the original pipes and a £2.69 delivered pie joiner from ebay


Ive driven many cars with the 1.8T petrol engine and in standard form i find it boring tbh. It pulls very well low down almost like a diesel the turbo spools up quick. But it never pushes you back in your seat flat out like a turbo car should. The diesel engine feels quicker due to the torque.

However my mate has an almost identical emocion red LCR 225 BAM engine same age as mine and their about the same speed.