I wussed out and cleaned everything up and just used the EGR as a plug for now (dissabled). Got a code, but computer battery died before I could pull it. I don't think the EGR was leaking at idle, but it seems that when it got a signal the exhsaust backpressure was probably blowing it too far/too long open - since the truck runs much better now. Still smokes on high fuel flow, but until I get time and charge, I won't know how far up that threshold has moved. I suspect the EGR was not really broken, but maybe the kitty is plugged enough to upset the EGR's apple cart. Will collect some data tomorrow AM and see where things have changed.
Also: what is in AE to use the pressure sender for vacuum on the firewall (the one that is teed off from the vac supply of EGR solenoid)? I think the vac pump is just not putting out enough. Here's the question: everyone selling vac pumps says you need to have 20" Hg or the pump is no good. At the wastegate actuator, I can see no more than 14" - and often not even that - thus one more reason it may not be able to build enough boost to burn all of the fuel (#9 resistor not helping there). I also read somewhere on the internet that the S wouldn't give ANY boost unless the transducer on the firewall saw 20". I threw a gauge on there for a while, and it was nowhere NEAR that (thus the desire to read it's output electronically).
Finally, regarding exhaust: I am an efficiency/airflow freak, so the stock exhaust just has to go. Kitty might be constipated, or it might not. If I am going to open it up to look, I will change out. Enough horror stories about the crossover pipe to get me onto that as well. I ordered a complete system and x-over from Hearthrob Exhaust in MN today. 2.25" crossover (as are flanges - thus right for turbo feed), 3" downpipe and 4" system with glass packed perf core straight thru. I told them I didn't really want a 4", but they said that they had built the 4 and it wasn't worth running a different size since few guys would realize that 3" is more than enough for a 200HP engine. I LIKE this company. Aluminized stuff, retails for under $500 (with x-pipe) and is the same system as several vendors sell (some as their own). Yeah, I really would like a fancy stainless system such as I have on Mamma's TDI, but this is my buddy's truck and not exactly new - but it sure is growing on me.
