Audi A6 2.7 & 3.0 TDi EGR & Intake system cleaning info please...

**gupsterg** · 01-02-2013,01:29 PM

Hi Jim,

Thanks again mate as always for support

... if it was not for you guys I don't know what I would have done

...

There are many reasons why I wish to be a lurker and not a poster... but mate not the thread for it...

The biggest anguish has been really how most instances of giving car for remedial work has ended in such poor results or attention to detail...

Everytime I have given car for work instead of hop skipping like Britney Spears...

I'm left picking up the pieces ... what I could do with her intake system! ...

Maybe once I've fixed car & had a break I'll be back to wreak havoc on-line!

...

ATB
Gup

**Sam** · 01-02-2013,03:23 PM

Hey Gup, if you leave VWAF, I'll find where you live (I actually will, don't ask how) and drag you back.

Consider this your first and last warning.

**Golfedd** · 04-02-2013,10:26 AM

Originally Posted by mycarsavw

Hey Gup, if you leave VWAF, I'll find where you live (I actually will, don't ask how) and drag you back.

Consider this your first and last warning.

haha that reminded me of

Just not as dramatic as we'd really just give you some tea, biscuits and a laptop with VWAF as it's homepage

**gupsterg** · 15-02-2013,07:10 PM

So yesterday I tried to get the EGR valve and connecting pipe to upper intake section off to view EGR cooler/flap unit without removing them...

EGR Cooler (Blue box), EGR cooling flap (Turq.box) & EGR Valve (Purple box)...

This was the view I was trying to achieve... but "In situ"...

So I thought undo these two...

Then these two..

But look at this (this is a metal pipe)...

Now here is a video showing its start/finish,etc...

Now what is this? coolant bleeder pipe

...

So in video above at about start (0.06/0.07) you will see a banjo bolt... there is another which I can't photo/video but is located approximately near the EGR cooling flap unit on engine block (red boxes below image)...

Now I'm not going to go into how much of a PITA removing the upper/lower manifolds are but you also seem to have to contend with the "Coolant bleeder pipe" at this point this happened Link:- I'm utterly depressed

...

So anyway I'm taking a break from mucking around with the EGR until I replenish the will to do it!

Because I'm feeling like this

& this

...

Mechanics must loathe V6 owners IMO!

**DieTryin'** · 16-02-2013,02:21 PM

Hey Gup

Do you have access to the ELSA workshop guide?

I've just had a look at EGR valve removal and the intake manifold (top section only) plus the vacuum hose attached to the valve are the only bits that have to come off to remove the EGR valve (no special tools listed either). Allegedly

!

The bolts holding the valve on are 25Nm torque so may need a bit of dismantling fluid to get them out as space is tight.

Sorry if you've already seen the workshop guide!

**gupsterg** · 16-02-2013,03:08 PM

Removing and installing bottom section of intake manifold (left-side) - vehicles from 08.2004 onwards

Then view the 8th image and ref with my video/photos...

I'm open to all suggestions at mo

...

**gupsterg** · 17-02-2013,03:18 PM

Right guys some more brainstorming

...

A thought crossed my mind that these "Metal coolant pipes" must be an issue when doing the swirl manifold replacement...

Link:- VW AUDI Forum - VWAF

Originally Posted by sparker

There is a cooler pipe on both sides with a bracket attached that is held in place with one of the manifold bolts, these can be carefully moved slightly and the manifolds lifted a little and twisted to get them out from under the pipes and wires.

Also ref video in post 46 (0:06/0:07)...

The side by the EGR...

So is my only option to remove complete intake manifold system, clamp coolant hoses, undo the EGR connecting pipe from turbo to EGR flap unit, remove bolts on mounting plates of EGR cooling system?

So I end up with this out of engine some how manoeuvred between the plethora of pipes/wires,etc... ...

**DieTryin'** · 17-02-2013,05:14 PM

Hmmm!

But Gup, is the EGR + cooler definitely the problem?

**gupsterg** · 17-02-2013,05:34 PM

A bit unsure at present

...

why? well

As I couldn't easily gain access to EGR system I've done some tests (each separately)...

i) removed hose to EGR valve, check MVB 03 so can see go out of spec wildly and correct spec once vacuum restored and valve operating... by this test I gather EGR valve not staying open and is opening when needed...

ii) removed hose to EGR cooling flap, check MVB 03 so can see go out of spec with very small amount and correct once vacuum restored, reasoning why it is going out of spec at idle is due to how cooler restrict EGR flow and at idle cooling flap correct default is straight through...

But also have another line of enquiring going Link:- Vacuum check valve