Hi all. My first Post. What an awesome forum!
I have a 00 Golf TDI w\ approx. 125,000 on her.
About the EGR system. The cooler plugs up because the blow by mixes with the exhaust and soot forming one hell of a carbon based resin which completely plugs up the cells in the EGR cooler. I remove my cooler whenever it gets plugged. A radiator shop runs a long drill bit though the cells, and soaks it in Simple Green, after this, they blow it out w\ compressed air and all the soot is removed. You could also remove it completely and just join the coolant lines, and plug the holes in the exhaust system. Of coarse your NOx would be through the roof, but you would never have to get it cleaned or buy a new one (which costs about $515) Dialing back the duty cycle with Vag-Com is a Band-Aid, and it will eventually plug up again. Ive never seen an EGR system plug up like this, I deal a lot with Heavy Duty off Highway Diesels. I never would have expected to see this in a tiny little Light Duty Diesel engine.