Too much EGR?

[Cory.Miller]

2002 Jetta ALH TDI: My issue seems to be too much EGR. At idle it smokes a lot and after 2 minutes when the EGR closes, the car runs better, but still doesn't make power (boost actual lower than boost requested). I tried putting a block off plate before the EGR cooler which resulted in the car idling great and revving smooth at idle, but when driving, it would through the overboost code before shifting into 2nd and going into limp mode. VCDS confirmed the over boost with EGR blocked and underboost with EGR setup normally. I did set EGR value to minimum of 33768 which didn't seem to change anything. Mass airflow actual reads lower then requested when EGR is unblocked, but actual reads higher than requested when EGR is blocked. I tried a new Bosch MAF sensor which didn't change anything. I've verified no air leaks in the EGR/boost system or vacuum leaks in the EGR/Boost solenoids Both solenoids appear to cycle properly by VCDS.

Previous issue with this car that appears to be fixed, but could be related since it hasn't ran right since the issue started:
https://forums.ross-tech.com/showthread.php?18452-ALH-TDI-VE-injection-pump-quantity-adjuster-test
Next I'll post log data of current relevant measure blocks.

Current Autoscan:

Sunday,18,August,2019,13:16:55:17120
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.1.0 (x64)  HEX-NET CB: 0.4508.4
Data version: 20190529 DS308.0
www.Ross-Tech.com


VIN: 3VWSP69M42M141714   License Plate: 


Chassis Type: 9M (9M - VW Jetta IV (1998 > 2014))
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
          75 76
 
VIN: 3VWSP69M42M141714   Mileage: 337350km-209619miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-012-AGR.clb
   Part No: 038 906 012 FD
   Component: 1,9l R4 EDC G500AG  4102  
   Coding: 00001
   Shop #: WSC 00066  
   VCID: 57FE8725B74F84F788-4B1E
   3VWSP69M42M141714     VWZ7Z0A4330857

2 Faults Found:
17056 - Cylinder 2 Glow Plug Circuit (Q11) 
            P0672 - 35-10 - Electrical Fault - Intermittent
16618 - Boost Pressure Regulation 
            P0234 - 35-10 - Limit Exceeded (Overboost Condition) - Intermittent
Readiness: 1 2 0 0 0 

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 01M-927-733.lbl
   Part No: 01M 927 733 MD
   Component: AG4 Getriebe 01M    4949  
   Coding: 00000
   Shop #: WSC 00000  
   VCID: 7EB0F28178B595BFEB-0964

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ABS.lbl
   Part No: 1C0 907 379 J
   Component: ABS FRONT MK60      0103  
   Coding: 0004097
   Shop #: WSC 00066 000 00000
   VCID: 312A19BDA96BBAC726-5184

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 F
   Component: 04 AIRBAG VW61 0202 0001  
   Coding: 12340
   Shop #: WSC 00066  
   VCID: 271EF7E5C7AFF477F8-513C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J0 920 906 M
   Component: KOMBI+WEGFAHRSP VDO V62  
   Coding: 07232
   Shop #: WSC 00000  
   VCID: 322816B1FC6D81DF5F-513C
   3VWSP69M42M141714     VWZ7Z0A4330857

1 Fault Found:
01304 - Radio 
            49-00 - No Communications

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00006
   Shop #: WSC 00066  
   VCID: 70ACDCB932E1F3CF69-513C

1 Fault Found:
01304 - Radio 
            49-00 - No Communications

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 C
   Component: 1H Komfortgerát HLO 0003  
   Coding: 00258
   Shop #: WSC 00066  
   VCID: 373E27A5170F64F768-4B1E

   Subsystem 1 - Part No: 1C1959801A
   Component: 1H Tõrsteuer.FS KLO 0004  

   Subsystem 2 - Part No: 1C1959802A
   Component: 1H Tõrsteuer.BF KLO 0004  

   Subsystem 3 - Part No: 1C0959811A
   Component: 1H Tõrsteuer.HL KLO 0004  

   Subsystem 4 - Part No: 1C0959812A
   Component: 1H Tõrsteuer.HR KLO 0004  

2 Faults Found:
01330 - Central Control Module for Central Convenience (J393) 
            53-10 - Supply Voltage Too Low - Intermittent
01333 - Door Control Module; Rear Left (J388) 
            53-10 - Supply Voltage Too Low - Intermittent

End----(Elapsed Time: 05:25, VBatt start/end: 11.9V/11.9V. VIgn 11.8V)-----

 

[Cory.Miller]

Not sure if this is the best way to paste the log data.

Here is when the EGR is hooked up normal. See boost specified is higher then boost actual:

Sunday	18	August	2019	13:23:32:17120-VCID:57FE8725B74F84F788-4B1E	VCDS Version: Release 19.6.1 (x64)	Data version: 20190529 DS308.0																		
038 906 012 FD	ADVMB	1.9l R4 EDC G500AG  4102																						
		G001	F0	G001	F1	G001	F3	G002	F1	G003	F1	G003	F2	G003	F3	G004	F1	G004	F2	G011	F1	G011	F2	G011
																								
Marker	TIME	Group 1 - Field 0	TIME	Group 1 - Field 1	TIME	Group 1 - Field 3	TIME	Group 2 - Field 1	TIME	Group 3 - Field 1	TIME	Group 3 - Field 2	TIME	Group 3 - Field 3	TIME	Group 4 - Field 1	TIME	Group 4 - Field 2	TIME	Group 11 - Field 1	TIME	Group 11 - Field 2	TIME	Group 11 - Field 3
	STAMP	Engine Speed - (G28)	STAMP	Injection Quantity	STAMP	Coolant - Temperature (G62)	STAMP	Accel. Pedal Pos. - Sensor 1 (G79)	STAMP	Air Mass - Specified	STAMP	Air Mass - Actual	STAMP	EGR Solenoid - (N18)	STAMP	Start of injection -  Specified	STAMP	Start of injection -  Actual	STAMP	Boost - Specified	STAMP	Boost - Actual	STAMP	Charge Pressure - (N75) Solenoid
		 /min		 mg/str		°C		 %		 mg/str		 mg/str		 %		 °BTDC		 °BTDC		 mbar		 mbar		 %
	1.38	903	1.38	7.6	1.38	48.6	1.74	0	0.3	395	0.3	255	0.3	19.9	0.66	0.9	0.66	1.5	1.02	999.6	1.02	969	1.02	45.8
	3.31	903	3.31	7.4	3.31	48.6	3.71	0	2.11	400	2.11	260	2.11	19.9	2.5	0.9	2.5	1.5	2.91	999.6	2.91	969	2.91	44.2
	5.16	903	5.16	7.2	5.16	48.6	5.52	0	4.08	390	4.08	265	4.08	19.9	4.46	0.9	4.46	1.5	4.8	999.6	4.8	969	4.8	42.2
	6.98	1029	6.98	10	6.98	48.6	7.33	11	5.88	390	5.88	250	5.88	19.9	6.24	0.9	6.24	1.5	6.6	1009.8	6.6	969	6.6	45
	8.93	1092	8.93	10.8	8.93	49.5	9.3	19.2	7.72	440	7.72	230	7.72	19.9	8.13	0.9	8.13	0.7	8.53	1020	8.53	969	8.53	24.7
	10.74	1155	10.74	11.6	10.74	49.5	11.1	25.9	9.66	465	9.66	225	9.66	19.9	10.02	0.9	10.02	0.7	10.38	1030.2	10.38	969	10.38	24.7
	12.55	1218	12.55	13.4	12.55	49.5	12.95	33.3	11.47	460	11.47	220	11.47	19.9	11.82	0.9	11.82	0.7	12.18	1050.6	12.18	969	12.18	28.3
	14.5	1260	14.5	14.2	14.5	49.5	14.86	34.1	13.35	525	13.35	165	13.35	19.9	13.76	2	13.76	1.1	14.14	1081.2	14.14	969	14.14	25.1
	16.3	1407	16.3	16.2	16.3	49.5	16.66	42.7	15.22	495	15.22	270	15.22	19.9	15.58	2.2	15.58	1.1	15.95	1101.6	15.95	969	15.95	26.7
	18.17	1722	18.17	17.6	18.17	49.5	18.57	57.3	17.02	605	17.02	180	17.02	19.9	17.38	4.2	17.38	3.1	17.77	1428	17.77	979.2	17.77	24.7
	20.08	1953	20.08	14.6	20.08	50.4	20.45	61.6	18.97	700	18.97	265	18.97	19.9	19.35	3.7	19.35	3.3	19.73	1489.2	19.73	1009.8	19.73	24.7
	21.88	2079	21.88	13.4	21.88	50.4	22.24	69.8	20.8	740	20.8	270	20.8	19.9	21.16	4.4	21.16	4.2	21.52	1652.4	21.52	1020	21.52	25.9
	23.81	2184	23.81	12.6	23.81	50.4	24.21	78.4	22.6	805	22.6	225	22.6	19.9	23.02	5.3	23.02	5.1	23.41	1815.6	23.41	1030.2	23.41	24.7
	25.68	2436	25.68	12	25.68	51.3	26.04	87.1	24.6	830	24.6	225	24.6	4.8	24.98	7.3	24.98	7	25.32	1948.2	25.32	1030.2	25.32	24.7
	27.47	2562	27.47	11.6	27.47	51.3	27.84	99.6	26.4	850	26.4	225	26.4	4.8	26.75	8.4	26.75	8.4	27.12	1948.2	27.12	1040.4	27.12	24.7
	29.42	2625	29.42	11.4	29.42	51.3	29.8	100	28.24	850	28.24	215	28.24	4.8	28.63	8.8	28.63	8.8	29.02	1948.2	29.02	1050.6	29.02	24.7
	31.26	2709	31.26	11.2	31.26	52.2	31.61	100	30.17	850	30.17	215	30.17	4.8	30.53	9.2	30.53	9.5	30.89	1948.2	30.89	1050.6	30.89	24.7
	33.06	2793	33.06	11	33.06	52.2	33.46	96.5	31.97	850	31.97	220	31.97	4.8	32.33	9.9	32.33	9.9	32.71	1948.2	32.71	1060.8	32.71	24.7
	35.04	2163	35.04	7.4	35.04	53.1	35.4	12.9	33.86	805	33.86	215	33.86	19.9	34.27	2.2	34.27	3.5	34.66	1122	34.66	1050.6	34.66	50.2
	36.83	882	36.83	6.4	36.83	53.1	37.21	0	35.76	350	35.76	250	35.76	20.7	36.11	0.9	36.11	1.3	36.47	999.6	36.47	989.4	36.47	30.3
	38.68	903	38.68	5.8	38.68	54	39.08	0	37.55	370	37.55	240	37.55	19.9	37.91	0.7	37.91	1.8	38.29	999.6	38.29	969	38.29	41.4
	40.59	903	40.59	5.8	40.59	54	40.97	0	39.5	375	39.5	255	39.5	19.9	39.87	0.7	39.87	1.8	40.24	999.6	40.24	969	40.24	41
	42.39	1281	42.39	14	42.39	54	42.75	44.7	41.31	375	41.31	245	41.31	19.9	41.67	0.7	41.67	1.3	42.03	1050.6	42.03	969	42.03	24.7
	44.3	1491	44.3	19.4	44.3	54.9	44.7	56.9	43.11	620	43.11	180	43.11	19.9	43.49	2.9	43.49	1.5	43.9	1234.2	43.9	979.2	43.9	24.7
	46.17	1974	46.17	13.8	46.17	54.9	46.53	69	45.09	720	45.09	200	45.09	19.9	45.47	3.7	45.47	2.6	45.81	1550.4	45.81	999.6	45.81	25.5
	47.97	2352	47.97	12.2	47.97	54.9	48.34	83.9	46.89	805	46.89	220	46.89	19.9	47.25	5.7	47.25	5.7	47.61	1887	47.61	1030.2	47.61	24.7
	49.94	2604	49.94	11.4	49.94	55.8	50.33	100	48.75	845	48.75	210	48.75	4.8	49.14	8.4	49.14	8.6	49.54	1948.2	49.54	1050.6	49.54	24.7
	51.77	2436	51.77	8	51.77	55.8	52.13	0	50.71	850	50.71	210	50.71	4.8	51.05	9.5	51.05	9.5	51.41	1560.6	51.41	1050.6	51.41	31.9
	53.57	882	53.57	5.8	53.57	55.8	53.96	0	52.49	335	52.49	290	52.49	22.3	52.85	0.7	52.85	1.5	53.22	999.6	53.22	989.4	53.22	41.4
	55.54	903	55.54	6	55.54	56.7	55.92	0	54.36	375	54.36	250	54.36	19.9	54.76	0.7	54.76	1.5	55.16	999.6	55.16	969	55.16	41

Here is when the vacuum hose on the EGR actuator is unplugged. the engine revvs normal, but if I drive it, it overboosts and goes into limp mode.

Sunday	18	August	2019	13:37:26:17120-VCID:57FE8725B74F84F788-4B3C	VCDS Version: Release 19.6.1 (x64)	Data version: 20190529 DS308.0																
038 906 012 FD	ADVMB	1.9l R4 EDC G500AG  4102																				
		G001	F0	G001	F3	G002	F1	G003	F1	G003	F2	G003	F3	G004	F1	G004	F2	G011	F1	G011	F2	G011
																						
Marker	TIME	Group 1 - Field 0	TIME	Group 1 - Field 3	TIME	Group 2 - Field 1	TIME	Group 3 - Field 1	TIME	Group 3 - Field 2	TIME	Group 3 - Field 3	TIME	Group 4 - Field 1	TIME	Group 4 - Field 2	TIME	Group 11 - Field 1	TIME	Group 11 - Field 2	TIME	Group 11 - Field 3
	STAMP	Engine Speed - (G28)	STAMP	Coolant - Temperature (G62)	STAMP	Accel. Pedal Pos. - Sensor 1 (G79)	STAMP	Air Mass - Specified	STAMP	Air Mass - Actual	STAMP	EGR Solenoid - (N18)	STAMP	Start of injection -  Specified	STAMP	Start of injection -  Actual	STAMP	Boost - Specified	STAMP	Boost - Actual	STAMP	Charge Pressure - (N75) Solenoid
		 /min		°C		 %		 mg/str		 mg/str		 %		 °BTDC		 °BTDC		 mbar		 mbar		 %
	0.71	903	0.71	66.6	1.07	0	1.43	375	1.43	430	1.43	84.5	0.01	0.4	0.01	1.5	0.35	999.6	0.35	969	0.35	41.4
	2.6	903	2.6	66.6	3	6.3	3.4	385	3.4	425	3.4	84.5	1.8	0.4	1.8	1.5	2.21	999.6	2.21	969	2.21	41
	4.49	1344	4.49	66.6	4.85	15.7	5.21	370	5.21	420	5.21	84.5	3.77	0.4	3.77	0.9	4.13	1009.8	4.13	969	4.13	24.7
	6.29	1701	6.29	66.6	6.67	18.8	7.03	375	7.03	425	7.03	84.5	5.57	0.9	5.57	0.7	5.93	1020	5.93	999.6	5.93	34.7
	8.22	1932	8.22	66.6	8.61	23.5	8.97	385	8.97	435	8.97	84.5	7.44	0.9	7.44	0	7.82	1060.8	7.82	1020	7.82	43
	10.05	2016	10.05	66.6	10.43	27.8	10.77	420	10.77	440	10.77	84.5	9.33	0.9	9.33	-0.2	9.69	1071	9.69	1050.6	9.69	47.4
	11.85	2373	11.85	66.6	12.25	29.8	12.64	435	12.64	430	12.64	83.7	11.13	1.1	11.13	0	11.49	1101.6	11.49	1091.4	11.49	55.4
	13.82	2604	13.82	66.6	14.19	32.5	14.55	470	14.55	435	14.55	68.1	13.04	1.5	13.04	1.5	13.46	1111.8	13.46	1142.4	13.46	57
	15.63	2877	15.63	66.6	15.99	37.6	16.35	520	16.35	440	16.35	4.8	14.93	2	14.93	1.8	15.27	1162.8	15.27	1203.6	15.27	61
	17.47	3906	17.47	66.6	17.86	32.2	18.26	850	18.26	390	18.26	4.8	16.71	5.9	16.71	4.8	17.07	1234.2	17.07	1336.2	17.07	69.7
	19.43	3948	19.43	66.6	19.77	33.3	20.13	850	20.13	390	20.13	4.8	18.65	9.7	18.65	9.9	19.04	1213.8	19.04	1336.2	19.04	68.9
	21.21	4074	21.21	66.6	21.57	33.3	21.93	850	21.93	390	21.93	4.8	20.49	10.3	20.49	9.9	20.85	1224	20.85	1356.6	20.85	70.9
	23.1	2247	23.1	66.6	23.5	0	23.89	370	23.89	445	23.89	74.5	22.3	6.8	22.3	9.7	22.71	1050.6	22.71	1224	22.71	67.3
	24.97	882	24.97	65.7	25.33	0	25.69	370	25.69	425	25.69	84.5	24.25	0.4	24.25	1.5	24.61	999.6	24.61	999.6	24.61	41
	26.77	903	26.77	64.8	27.13	0	27.5	370	27.5	420	27.5	84.5	26.05	0.4	26.05	1.5	26.41	999.6	26.41	979.2	26.41	41
	28.71	903	28.71	64.8	29.08	0	29.45	375	29.45	425	29.45	84.5	27.9	0.4	27.9	1.5	28.3	999.6	28.3	969	28.3	41.4
	30.53	903	30.53	64.8	30.9	0	31.25	375	31.25	430	31.25	84.5	29.81	0.4	29.81	1.5	30.17	999.6	30.17	969	30.17	41
	32.33	903	32.33	64.8	32.71	0	33.12	375	33.12	425	33.12	84.5	31.61	0.4	31.61	1.5	31.97	999.6	31.97	969	31.97	41
	34.3	903	34.3	64.8	34.68	0	35.03	375	35.03	425	35.03	84.5	33.52	0.4	33.52	1.5	33.92	999.6	33.92	969	33.92	41
	36.11	903	36.11	65.7	36.47	0	36.83	375	36.83	430	36.83	84.5	35.4	0.4	35.4	1.8	35.75	999.6	35.75	969	35.75	41
	37.97	903	37.97	65.7	38.36	0	38.76	380	38.76	430	38.76	84.5	37.19	0.4	37.19	1.5	37.55	999.6	37.55	969	37.55	41.4
	39.9	1281	39.9	65.7	40.25	20	40.61	375	40.61	415	40.61	84.5	39.15	0.4	39.15	1.3	39.53	1009.8	39.53	969	39.53	24.7
	41.69	1911	41.69	65.7	42.05	25.9	42.42	405	42.42	440	42.42	84.5	40.97	0.9	40.97	0.2	41.33	1050.6	41.33	1009.8	41.33	37.1
	43.57	2184	43.57	65.7	43.98	31.8	44.37	450	44.37	445	44.37	82.5	42.78	1.1	42.78	-0.9	43.19	1091.4	43.19	1081.2	43.19	51.4
	45.44	2688	45.44	65.7	45.8	32.2	46.18	470	46.18	435	46.18	66.1	44.73	1.5	44.73	1.1	45.08	1132.2	45.08	1173	45.08	61.8
	47.25	2919	47.25	65.7	47.61	33.3	47.98	485	47.98	425	47.98	19.9	46.52	2.4	46.52	1.8	46.88	1142.4	46.88	1224	46.88	63.4
	49.17	3339	49.17	65.7	49.56	33.3	49.93	850	49.93	405	49.93	4.8	48.37	3.7	48.37	3.3	48.77	1173	48.77	1254.6	48.77	65.3
	51	3549	51	66.6	51.36	32.2	51.72	835	51.72	400	51.72	4.8	50.28	7.5	50.28	8.4	50.66	1173	50.66	1285.2	50.66	66.1
	52.81	3843	52.81	66.6	53.21	33.3	53.61	850	53.62	390	53.62	4.8	52.08	7.7	52.08	7.5	52.44	1213.8	52.44	1305.6	52.44	69.3
	54.8	4095	54.8	66.6	55.19	32.5	55.52	850	55.52	385	55.52	4.8	54.01	10.3	54.01	11	54.41	1224	54.41	1356.6	54.41	72.9
	56.6	2625	56.6	66.6	56.96	0	57.32	335	57.32	460	57.32	84.5	55.88	6.6	55.88	8.8	56.24	1060.8	56.24	1224	56.24	68.5
	58.45	882	58.45	65.7	58.85	0	59.25	370	59.25	430	59.25	84.5	57.68	0.4	57.68	1.5	58.06	999.6	58.06	1009.8	58.06	41.8

 

[MasterTommy]

I don’t feel confident enough in this case to give you any detailed advice, but what makes you think the problem is the EGR system?

 

[Jack@European_Parts]

Fix the positive deviation by maybe checking WG settings as per RTFB & or unplugging the intake of carbon or restriction in boost pipes?

JPPSG

 

[Cory.Miller]

I have solved the mystery! I found that the vacuum line that is supposed to supply fresh air to the boost and egr regulator solenoids was not hooked up to the air box as intended. Instead, it was plugged and held in place with this add fitting.
https://photos.google.com/u/1/photo/AF1QipNBsYZoutpo-weQ8m4KUnHa3GEMdAS-j0Y-3pB5

When I saw this before I assumed the fitting let air through was was an alternative to plugging into the airbox. Once I found that this fitting it a plug and prevented the solenoids from breathing fresh air, I knew this must be the issue. I know it has been like this before the initial failure of vacuum line to boos actuator. All I can think is there must have been a vacuum leak somewhere else to let the system breathe. Either way, long problem solved. In case this wild string of failures helps others or should be posted to a separate thread for others to find, here is the summary of my long saga with my 2002 Jetta MKIV TDI ALH - VIN: 3VWSP69M42M141714 Mileage: 337350km-209619miles....

1. Initial problem was low power due to collapsed vacuum line to boost actuator. I drove the car about 80 miles trying to diagnose the issue, and I think the engine without boost worked hard and hot which caused other issues as found described below.
I replaced all small vacuum lines, and while the car was still on the lift, I fired it up, heard the turbo whine again :-) but then the car started running rough and smoking and died.

2. After that the car would only crank but not fire, which sent me on several weeks of tracking down this issue. During this time I ordered my new VCDS cable (last one was kept by VW friends in Milwaukee when I moved away). At this time I posted this string: https://forums.ross-tech.com/showthread.php?18452-ALH-TDI-VE-injection-pump-quantity-adjuster-test
Through all this I found 3 potential issues, Relay 109 was bad (maybe caused by probing with multimeter in the dark), bad wire in drive door hinge causing CCM error codes, and the main issue, a bad injection pump quantity adjuster. I tried everything with the pump, including a in depth tear down and reassembly looking for mechanical damage of which I found none. The case pressure relief valve let loose which I fixed, then replaced, which did not fix the issue. After much more troubleshooting I concluded it must be an issue with the pump quantity adjuster. I bought a scrap car for $100 which had an injection pump with yellow marks showing it was never removed, so I took a chance and with this pump, the car fired right up. Timing belt, and water pump kit replaced at this time. Injection timing set and verified with VCDS (so slick!). I should mention that in the replacement pump, I found the case pressure relief valve let loose which may be why the car was sold for parts. Someone else pulled out the manual trans before I got it for the engine. That car had 310,000 miles so I will be scrapping the rest of it.

3. Now that Jetta starts again, but blows clouds of white smoke, and has no power. After a few more weeks of troubleshooting and taking breaks to prevent my frustration from burning the thing down, I found the wastegate vanes were sticky. So I removed turbo, EGR, Intake manifold and thoroughly cleaned everything. I replaced the boost actuator and set the wastegate to operate between 5 and 25" with the mighty-vac. Now jetta runs better, but still low on power. VCDS showed boost actual didn't match boost requested. More troubleshooting led me to try a blockoff plate in the EGR and this resulted in boost actual being higher than boost requested and creating an overboost limp mode. I put EGR back to normal, and turned it all the way down with VCDS. After much more troubleshooting I found...

4. As stated above, the darn vacuum line fitting blocking the fresh air supply to boost and egr solenoids was the issue. After plugging this line into the airbox as it should be, Jetta is back to running great. As excited as I was to sell that thing, I just might keep it again now! Actually, I think I'll sell it and buy an MKIV TDI with stick shift.... now that I think I can fix any future issue with these cars much faster next time.

Thanks again for all the help!

 

[Jack@European_Parts]

Isn't that not fresh air & is vacuum under throttle intake & by venturi effect of a restricted orifice & to assist the vacuum pump and why the nipple is above the air cleaner not below it, it is also why when you hooked it up it sealed the vacuum leak for both?
Did you also see your accumulator for function?