[glitdi]

First off big big thanks again to Yosh, he is my local 335d guru and like a lot of people here his experiences and advice have been invaluable. Thanks again!!

So Yosh gave me a egr that he got off another member that was damaged. I wanted to use it to take measurements for the turbo side block off and to build a clean delete for the coolant lines. I know guys are leaving the egr system and just using plugs but I am concerned that eventually the coolant will leak through the egr and into the exhaust. You can do this mod with your egr system however its impossible to return back to stock.
I got lucky by having a spare, so just be aware that free co.mes with a price.
So here goes....
I dont have pics of the block off plate on the intake side however its pretty self explanatory...
I took a piece of stainless plate and some copper and removed the pipe and traced the outline on the steel plate. I cut it cut the gasket and sandwiched the plate between the flange in question and the intake for the exhaust gas to enter the intake. If pics needed I can get some.
I then took the old broken egr that I had cut off the turbo side pipe and used a lathe to machine down a plug, turned it down and tig welded the plug to seal the turbo side of the egr system.
I cut the two unions for the coolant lines and tig welded them together...
I haven't gotten around to installing them yet but will get to it eventually.
Problem with being a heavy duty mechanic is always fixing other peoples stuff...Whats the saying about shoe makers children? On that note my child, 335d gets neglected unfortunately, sometimes bieng a mechanic isnt what its cracked up to be..
Anyways a picture is worth a thousand words..





If by any reason these images dont work let me know, I may be a decent mechanic, I am not the greatest at "interneting"
Hope this helps someone else.

[Puerto Rican 335d]

great job NOW how are you going to decode the ECU?

[BB_cuda]

That last photo looks familiar. Those tips are imitation of the spigots on the EGR cooler. Looks like you guys took my idea one step further to eliminate the pipe threads, elbows, and pipe in between the spigots.

Does this put a lot of stress on the two black plastic lines? I'd be curious to get a picture of the double headed spigot installed onto the two plastic lines please.

[Lexx.md]

Originally Posted by BB_cuda

That last photo looks familiar. Those tips are imitation of the spigots on the EGR cooler. Looks like you guys took my idea one step further to eliminate the pipe threads, elbows, and pipe in between the spigots.

Does this put a lot of stress on the two black plastic lines? I'd be curious to get a picture of the double headed spigot installed onto the two plastic lines please.

I believe it is not just imitation, it is the actual EGR cutoffs and welded together.

Anyway this method couldn't be called cheap, as it ruins EGR cooler, and needs some welding skills.

Much easier will be just to put a piece of hose.

[iaknown]

Just a side note, with the EGR block-off kit that is readily available, it is physically impossible for the EGR to leak coolant into the motor, either through the exhaust or the intake. With the way that the plug and disc are installed the coolant has no choice but to fall outside the engine. This is of course providing the EGR would ever fill up with coolant which is nearly impossible.

[BB_cuda]

Originally Posted by Lexx.md

I believe it is not just imitation, it is the actual EGR cutoffs and welded together.

Anyway this method couldn't be called cheap, as it ruins EGR cooler, and needs some welding skills.

Much easier will be just to put a piece of hose.

Lexx,
I get your point that not just anyone can get a "junk" cooler. This is in fact what i did from buddy who is service tech at local BMW dealer. I asked him to keep an eye out for next cooler changeout and to put junk part to side. He did this for me and i paid him a small token of appreciation. I cut off the spigots and produced a drawing to replicate them but with pipe threads on the ends. You know the rest of that story. I wanted to recreate geometry of spacing of the two spigots relative to each other to not stress the hoses.


Glitdi, I'm still wondering how the black lines won't be stressed too much by doing this though. I built a shorter version of the pipe with elbows and felt the passenger side line was getting bent too hard. Heat and load over time likely may fail a plastic part. Just my opinion though. I returned to the longer pipe version.

You might take a look at what TDI did with merely blocking off each black hose with a stainless bolt (other important details too). There is necessary butchering of the black hose's connectors though. He hasn't had any leaks or high temp problems to date.
Here is the specific entry in that thread where he explains what he did.
http://www.e90post.com/forums/showpo...3&postcount=72

[glitdi]

Originally Posted by Puerto Rican 335d

great job NOW how are you going to decode the ECU?

Thats my engine tuners problem... He owes me a few favors anyways.

Originally Posted by BB_cuda

That last photo looks familiar. Those tips are imitation of the spigots on the EGR cooler. Looks like you guys took my idea one step further to eliminate the pipe threads, elbows, and pipe in between the spigots.

Does this put a lot of stress on the two black plastic lines? I'd be curious to get a picture of the double headed spigot installed onto the two plastic lines please.

Thank You!
I wil end up cutting them apart after that painful welding and splice a hose to stop the potential failure part.. will post pics when I actually get to it..
Thanks for the advice all!

I am aware its a messy way to go but just wanted to give options... Just another way to skin a cat, if you don't need the egr cooler why not? at the end of the day all it really cost me was time...

[Puerto Rican 335d]

glitdi jajaj thats a good one let him try to open the box its not as easy as it looks

[glitdi]

Originally Posted by Puerto Rican 335d

glitdi jajaj thats a good one let him try to open the box its not as easy as it looks

yeah he warned me.. said its going to look like a dog chewed on it.. Said its harder to crack open than the Zodiac Killer case....

[Puerto Rican 335d]

jajaj I've seen Lenny do mines 3 times and TRUST ME its easy at all