VAC HOSE

[BUSHPIG]

the vac hose's in the engine bay of my 2.8tdi bighorn what can i remove and what do i have to keep?
at the moment all ive got is the line from to the injector pump to the intercooler and the line from the turbo to my wastegate. it seams to be running good as but wanna be shure i can ditch all the crap b4 driveing it to much

[geeves]

Just had a look at mine. I have a vacuum line that goes to the valves behind the fuel filter as well. These were for the EGR which has been removed so the valves and line are now just for show. There is also a line from here back to the butterfly in the intercooler mount. Dont know what this is for but mines been seized open for many years. These 2 look like they are optional. Also there should be a large vacuum pipe to the brake booster. This one is very necessary if you like being able to stop

[BUSHPIG]

sweet m8 thx for that. yeh i think the butter fly in the intercooler is part of the exhaust brake thingy on the cast iron turbo down pipe. what im planing for thoes to butter flys is to runn the vac live into a tpiece on a solinoid on a switch and relay to the brake. and run the vac line fron the alt to the other input and hey presto a engine brake on a switcth(when on u hit the brake and it engages) and when of it should act like normal i think? well i think it should from from what info i found on google

[mulover]

You are on the right track there bush pig, exhuast brakes are very simple. Only thing is i'm not sure if the butter fly closes the exhaust off enough to make a difference. Just remember to let your engine fully warm up before using it.
You could hook it up to your accllerator if you wanted, when you lift your foot right off it activates??, Most of the ones in bigger trucks work like this.

[BUSHPIG]

hey thats not a bad idea going of the gas pedal. its already gt a micro switch on the gas pedal. ive dove a small test by just switchn it on when i back of the gas by getn a m8 2 just flick a switch thats hard wired and it seams to help a bit

[geeves]

The butterfly in the exhaust is not an exhaust brake. It is part of the cold weather cold start system. Its real job is to reduce warm up time but as it only works when the water temp is below 5C and the switch on the dash is on your unlikly to ever need it in Auckland.
Using it as an exhaust brake has been discussed before but never more than therory. To my knowledge no one has actually done this mod yet.

[BUSHPIG]

yeh ive already ditched all thoes solinoid's that control it to make room for my planed snorkle. im in the prosess of trying to make a exhaust brake with it ill let every one know how i got on and if it works ill be doing a write up with pic's

[muzila]

I have disconected all the little vac hoses and connected the intake pipe after the turbo to the fuel pump and blocked the alternator little pipe off.

That should work ok shouldnt it? I cant start my truck up yet as the alt is still out and a few other bits are dissconnected.

[geeves]

Check the turbo hasnt siezed Check that the warm up device in the exaust isnt jammed on.
If you remove the intake pipe from the turbo can you see the impeller spinning from just over idle.(be careful with this test The turbo will vacuum up anything in reach and any small bolts going through turbo result in a big expensive bang)

[jellis]

Hey Bushpig slightly different topic but how did you remove your egr as i needed to disconnect all the hoses when i was playing around installing a new gearbox and replacing perished water lines.. Now my car wont rev over two grand and the turbo won't engage. Cars been of the road for four months, and i thought filling the gearbox with oil was the last freaking thing i would have to do!!!!!!

this is exactly what happened with mine once i took the egr valves and stuff off it worked perfectly.

[muzila]

I finally got my mu running last night. After taking all them valves out and hoses it goes like a rocket now. I still want to get rid of a few other things under the bonnet but thats for a differant thread.

[ezytiger83]

I have disconected all the little vac hoses and connected the intake pipe after the turbo to the fuel pump and blocked the alternator little pipe off.

That should work ok shouldnt it? I cant start my truck up yet as the alt is still out and a few other bits are dissconnected.

hi mate, just to be certain, did you ditch EVERYTHING else? i bought my 2.8TD MU with the EGR deleted and blanked already and a 2nd battery behind the air filter. I think this is a common mod, where the vacuum bundle is moved right into the corner. i'm keen to ditch the nest of shitty vacuum hoses, so was wondering if u could throw up a pic of what you left in?

There's a couple of electrical relays in the nest too, did you keep these?

[jezza]

I've removed all of my airlines and solenoids under my bonnet, all I've got is the boost line to my gauge and to the compensator

[dasnoboarder]

I've done the same as Jezza, just wondering if anyone has tried to remove all the wiring as well?

Mine's just hanging there tied to the firewall.

[muzila]

I have disconected all the little vac hoses and connected the intake pipe after the turbo to the fuel pump and blocked the alternator little pipe off.

That should work ok shouldnt it? I cant start my truck up yet as the alt is still out and a few other bits are dissconnected.

hi mate, just to be certain, did you ditch EVERYTHING else? i bought my 2.8TD MU with the EGR deleted and blanked already and a 2nd battery behind the air filter. I think this is a common mod, where the vacuum bundle is moved right into the corner. i'm keen to ditch the nest of shitty vacuum hoses, so was wondering if u could throw up a pic of what you left in?

There's a couple of electrical relays in the nest too, did you keep these?

Sorry for late reply been disconnected from the net for a month. (dicks cut the cable outside diging up the road.)

Yup I pulled everything out, even the brakets bolted there as I mounted the fuel filter there.

Heres what I did so all can see.

These are the blanks made from the templates posted elsewhere on this forum.

Image0005.jpg

Image0006.jpg

Removed all the vac hoses and everything in that corner.

Image0007.jpg

Took a length of vac hose and attached it here after the turbo.

Image0008.jpg

And ran it to here. The fuel pump.

Image0009.jpg

That small bolt is jamed up the small vac hose from the back of the altinator.

Image0010.jpg

And that was it. I havn't removed the electrics and plugs yet, They can stay there until I pull the body off and rip the whole truck apart next winter for its total rebuild.

I just have to remove the water bottle and tidy up the brackets and snorkel hose then I kan make the tray for the second battery.

Anyway I hope it helps someone out.....

[ezytiger83]

cheers mate, top photos, very helpful

[Yarno]

If you plan to have A/C still, you need one solenoid that goes to the idle up actuator.

Grey Solenoid


Actuator

[daisy]

[quote="Yarno"]If you plan to have A/C still, you need one solenoid that goes to the idle up actuator.

A/C still works with out that solenoid just idles a bit low if yourve got the air con on when idling but when driving doesnt matter. just rip it all out

[ezytiger83]

thanks for that guys if i'd taken my laptop into the garage with me, i might not have ripped it out with quite so much gusto ...i like how simple it's lookin now, will test the aircon tomorrow before i play around with puttin old grey back in.

*UPDATE* no need for the grey solenoid in my 2.8 it easily handles the aircon. i would highly recommend this mod! egr? pfffffff, it's a parasite on your engine

[muzila]

Oh yea I forgot about the aircon. I dont have it as I ripped it all out.

I just kept the aircon pump to turn into an air compressor when I figure out how to do it and set it all up.