[Sams Village]

If you are one of the lucky ones with alloy Y piece, then you could burn it clean:

it took years to build up so cleaning will take some time. When i replaced egr cooler, i decided to do some preventative maintenance. I tried oven cleaner on the plastic swirl flap manifold. It took ages, was very messy and gave up after 4 sprays, brushes and rinses. I could still scrape bits off with a screw driver but was worried something might dislodge into cylinder so I left it as is. It was no where near totally blocked to begin with though. i I did not try burning alloy intake as that looked ok apart from egr hole for which I scraped clean with a screw driver. How can this be better for environment unless the theory is to bin those caked up parts. Egr delete might be on the cards soon me thinks.
BTW - Plastic = more parts sales for vw

 

[Sams Village]

I suppose you need to eliminate one or the other but wouldn't it be better to get rid of soot from egr? Maybe you lose lubrication properties to turbo,swirl flaps and cylinder valves by installing a Catch Can?

 

[Sams Village]

Sorry Bloc. Just to be clear, all that blockage at 100k miles or km? If km then blockage seems excessive to me.

 

[Sams Village]

Hi Mark, can you throw up some photos to help describe where and what you are doing? Is it at the end of egr system? I imagine all this work at the beginning of egr system would be very labour intensive.

 

[Sams Village]

Nice. Keep us posted

 

[Sams Village]

Will do. Wife left this morning for a 2hr one way shopping trip. She reported she made it about 100kms before CEL. Gaining approx 40km per drill size now. Who knows, it might just be a temp thing or maybe it will work long term. Best thing is nothing gets damaged or modified. Can simply put back to stock if this doesn’t work

did the CEL come on at high speeds/revs?

Id be curious to know what the resistance is of the egr sensor at cold, normal operating and after some time at 100km/h without any mods. Then take same readings with mods installed. Might be a simple resistor fix by bypassing egr temp/flow sensor? My guess is with the mods, the sensor does not detect egr flow gasses as being hot enough ie, insufficient flow CEL. Assuming this is your error code?