Egr leaking what to do

[Big_daddy]

The last few weeks noticed my alhmabra (1.9 PD TdI- stage 1 remap) drop in power and torque, plus i could hear my waste gate chatter when i come of boost.

When i was fitting the dieltric grease noticed this on EGR covered with oil around it.
Think its leaking as well hence the turbo chatter sound.

Any suggestion on how to fix it? dont want to strip the part and dont have a clue what to do with it? Done a search but nothing to my relevant.

 

[UncleFester]

I would suspect it wants removing and cleaning out, how old is the car and how many miles has it done?

 

[Big_daddy]

Its 2000/2001 model, just hit 110k
Would i need new gasket of any sort?

 

[UncleFester]

I don't know as i've not had mine off however there's probably a 'howto' on here and if there isn't, there will be one on the tdiclub forums. At that age and mileage it's probably due for it.

 

[Big_daddy]

Ive managed to get the egr valve of and gave it a good clean (done my best). It was quite dirty but dont think it stricted airflow.

1. Can any know how remove the manifold so i could give a whip clean. Nothing comiong up on the search.

2. Abit concerned, the rubber seals looks abit flat , any know if i cant get the seal for the egr valve seprate or is part of the egr valve it self?

 

[UncleFester]

I would be very careful if you remove the manifold - you really don't want that crap coming loose and getting into the engine. Was the valve that works inside the EGR fouled up at all?

 

[Big_daddy]

I would be very careful if you remove the manifold - you really don't want that crap coming loose and getting into the engine. Was the valve that works inside the EGR fouled up at all?

Thats true, one reason i dont want to remove it, 2nd the lack of room under that bonnet is putting me off.
The flap seems to be working fine, havent really check the egr 1 yet. how can i check? does it be open on vacum or closed?

 

[UncleFester]

I think vacuum will open it - i.e. pull the rod / linkage upwards although i could be wrong. I'd be inclined to reassemble it and see if it leaks again.

 

[Big_daddy]

Will resasemble it shortly, fingers crossed every tings goes well.

 

[ChrisGTL]

Ive managed to get the egr valve of and gave it a good clean (done my best). It was quite dirty but dont think it stricted airflow.

1. Can any know how remove the manifold so i could give a whip clean. Nothing comiong up on the search.

2. Abit concerned, the rubber seals looks abit flat , any know if i cant get the seal for the egr valve seprate or is part of the egr valve it self?

How the hell did u manage to remove your EGR? Do I have massive hands or something? I need to try harder!

Is it just 3 allen bolts you remove to completely take EGR off? Any other tips? Did you remove anything to make it more easier?

 

[Big_daddy]

How the hell did u manage to remove your EGR? Do I have massive hands or something? I need to try harder!

Is it just 3 allen bolts you remove to completely take EGR off? Any other tips? Did you remove anything to make it more easier?

I didnt say it was easy! you cant use BIG rachets, i had brake a long hex key so i could jam it into the socket as the rest were too wide. Took 40mins to remove just tose 3 nuts, plus i keep droping the dam thing on the mud guard

Theres not much you could remove for access, i moved fuel filter abit down as it would be headce to remove plus the time period i had. remove map sensor pipe. i couldnt get access to the two bolt under egr valve so i jsut remove the pipe joint further down, ( much easier).

Hope this help, (ive runined all my whites , like working on a steam engine)

 

[ChrisGTL]

I didnt say it was easy! you cant use BIG rachets, i had brake a long hex key so i could jam it into the socket as the rest were too wide. Took 40mins to remove just tose 3 nuts, plus i keep droping the dam thing on the mud guard

Theres not much you could remove for access, i moved fuel filter abit down as it would be headce to remove plus the time period i had. remove map sensor pipe. i couldnt get access to the two bolt under egr valve so i jsut remove the pipe joint further down, ( much easier).

Hope this help, (ive runined all my whites , like working on a steam engine)

I've bought myself some new hex keys that are much shorter than my previous set but they still look too long to get in that tiny area.

My problem was getting to the 3rd 'hidden' hex bolt, I got the obvious 2 out in no time, then tried to get the bottom two bolts out to make it easier (I was trying anything) but they are even harder to get to than the 3rd EGR bolt.

Should it fall off when I've removed the 3rd bolt or do you have to swing on it to remove the EGR?

 

[Big_daddy]

I've bought myself some new hex keys that are much shorter than my previous set but they still look too long to get in that tiny area.

My problem was getting to the 3rd 'hidden' hex bolt, I got the obvious 2 out in no time, then tried to get the bottom two bolts out to make it easier (I was trying anything) but they are even harder to get to than the 3rd EGR bolt.

Should it fall off when I've removed the 3rd bolt or do you have to swing on it to remove the EGR?

Two get the the 3rd screw, using a long extensions just under the fuel line and use small ratchet, theres decent room for ratchet to spin.

whne all 3 nuts removed, it still abit stiff as the xhaust pipe is still attached, remove the two bolts on pipe, but remove the vacum lines at the top before hand. you just then wiggle it out, the exhaust pipe would be still attatched to it.