EGR valve removal

[PeteK]

Yes, the 3 bolts secure it to the inlet manifold and it should just separate with no issues once you have removed the pipe that goes into the EGR at the back of the engine and also the pipe that comes from the exhaust to the EGR valve.

[fordsmith]

First of all just unwired the the EGR from the cable, it is very easy just push one pin and you will done. Now undo the jubilee clips from the other end of the hose. Don't throw away it because you will need it. Now next remove the allen bolts to unbolt the EGR valves. The bolt will be tight because coating on it. After removed the bolt now you can keep out the EGR valve.

[powerband]

Found your post really useful, just done my EGR and manifold but unfortunately my car is still bellowing black smoke and won't pull the skin off a rice pud; I've got a couple of P codes to Google but I reckon my EGR valve is kapput.

[shegan]

anyone know of any how tos for the manifold removal? I took the EGR off at the week end and cleaned it but hadnt a clue where to start removing the inlet manifold.

Will cleaning the parts out boost efficiency or anything?

[powerband]

I think the exhaust manifold could be a bit tricky to remove in that you'd have to remove plenty of other items to get access.
I removed my EGR valve with pipe attached (the one with the flexible joint in the middle), I then removed 6 cap head (allen bolts) to remove what I would call the upper manifold which the EGR valve pipe attached to. I used a pipe brush to clean all the deposits out of this which was less encrusted than the valve.

[shegan]

aye, thats the one im on about. wasnt too sure if it was just a case of removing the allen bolts to take it off.

[powerband]

Yes that's it, 6 allen bolts then just lifts out, don't know if cleaning the EGR valve and manifold will increase efficiency but it won't do any harm unless of cousre your unfortunate to damage something.

My Passat is now in a garage and they've found the air booster valve has an intermitant fault which might be causing my black smoke and poor running if replacing that doesn't work then it's a new EGR Valve :-(

[PeteK]

After doing this last year my fuel consumption improved by about 2 mpg on average, I suspect that it may be the new coolant temperature sensor I fitted at the same time that helped though. Even with that fitted, the coolant temperature reading displayed on Vag-Com and the diagnostic mode on the Climatronic unit was struggling to get above 75C - I finally cured that a couple of months back by fitting a new thermostat and now it stays at a constant 87-89C when fully warmed up.