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Alright, so from all that reading, it looks like we have two issues with running large amounts of EGR.
1) Fuel mixture dilution causing misfires and/or incomplete burn.
2) Hot EGR gas causing detonation.
#1 is going to be unavoidable. A high swirl/tumble head will probably help to some extent (or direct injection).
#2 is avoidable with some sort of EGR cooler. I know they use these on diesels. Can any TDI owners pipe up with any info on these systems? It looks like they run coolant through a heat exchanger to cool down the EGR charge.
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