EGR Valve and Manifold

[SportAvant]

Hi

I have recently had a service carried out by Audi (thats the first and last time I go to the main dealer) on my 04 a4 avant 1.9 tdi 130 which has just covered 75k. The technician said that the EGR valve and manifold needed replacing and that oil was leaking into it or from it I can't remember exactly what he said but it would cost £240 to replace. I asked him if this was a common fault to which he responded that it is wear and tear and not a fault. Does anybody know if an EGR valve should go for a car thats done 75k, is that reasonable wear and tear? The car has full Audi main dealer service history. I can't seem to find anything in the forums re this. Any help would be much appreciated.

:1zhelp:

[Col]

Very common problem.

My 130hp Passat has been doing this ever since I've owned it (over 40k, now on 137k) with no problems except the mess.

What you can do are several things;

1, Replace the EGR valve, an easy DIY job.

or

2, Unplug the vacuum line from the EGR and plug the open end. This is what I have done and it greatly reduces the oil weepage (if you look the oil will be leaking from the two diaphragm vent holes on the top, one either side). I've had this little mod running on mine for 30k of the 40k I've had the car, it runs fine and passes the MOT fine by the way.

You may also want to do a search on here about removing and cleaning the EGR valve which could also help you decide what you want to do. But for the sake of maybe a couple of hours of your time you could solve this yourself, save a fortune and the best bit is that your Mrs will think you are a car-fixing-superhero !


As for replacing the manifold, I think Audi are taking the wee-wee, simply get some gunk or de-greaser, a pressure washer and clean it !

[SportAvant]

Thanks for that BigCol.

For me to remove and clean or replace the EGR valve I would defo need detailed instructions as I am a novice. GSF do the EGR valve for about 110 quid so if I could diy it that would save me over a £100. Does any one know where I can get instructions preferably with pics? Would be a great help if anyone did.

Any help greatly appreciated!

[stonedagain]

Thanks for that BigCol.

For me to remove and clean or replace the EGR valve I would defo need detailed instructions as I am a novice. GSF do the EGR valve for about 110 quid so if I could diy it that would save me over a £100. Does any one know where I can get instructions preferably with pics? Would be a great help if anyone did.

Any help greatly appreciated!
Save yourself the bother & blank off the vac pipe as Big Col suggested. I did this months ago on my tdi Passat & it runs much better. No black smoke, cured hesitation/flat spots, & just flown through MOT.

[SportAvant]

Cheers guys

I think I will save the cash and do what you have suggested:approve:

[Sureshd300]

I have the same problem. I would like to bypass the EGR too. How should I do this. I am sorry but I am a novice which need abit more instructions how to remove and close the EGR lines. Please do help me.

[stonedagain]

I have the same problem. I would like to bypass the EGR too. How should I do this. I am sorry but I am a novice which need abit more instructions how to remove and close the EGR lines. Please do help me.
Just remove the small rubber vacuum hose from top of the EGR valve, then push a 10mm bolt into the hose to block it off.

[zollaf]

As for replacing the manifold, I think Audi are taking the wee-wee, simply get some gunk or de-greaser, a pressure washer and clean it !

the sludge will be on the inside of the manifold, so do as bigcol says, but remove it first.

[Sureshd300]

Just remove the small rubber vacuum hose from top of the EGR valve, then push a 10mm bolt into the hose to block it off.


Thanks for the help. I will try doing it after work today.

:beerchug:

[Sureshd300]

Just remove the small rubber vacuum hose from top of the EGR valve, then push a 10mm bolt into the hose to block it off.


I have done it. Hope I got it rite. the white smoke when the engine is ideal is not there any more. Does this shut down the turbo too.

I have attached a pic after removing the EGR line. Please let me know if I have got it rite.



http://www.creoz.co.uk/suresh/DSC00832.JPG

[Sureshd300]

I just drove the car around and found out the turbo is working fine. and less black smoke but it was on traffic, So yet to see.
However the hard start is still there. I have to crank about 5 to 10 sec's for it to start up the engine. How can this be fixed.

[Col]

I just drove the car around and found out the turbo is working fine. and less black smoke but it was on traffic, So yet to see.
However the hard start is still there. I have to crank about 5 to 10 sec's for it to start up the engine. How can this be fixed.

Probably by changing the coolant temp sensor.

[Sureshd300]

You think the hard start is there coz of a fault in the coolant temp sensor. Please let me know where to find it. As. I am a novice to these stuff.

However I don't get any errors on the VAG COM.

[tyberwan]

I have done it. Hope I got it rite. the white smoke when the engine is ideal is not there any more. Does this shut down the turbo too.

I have attached a pic after removing the EGR line. Please let me know if I have got it rite.



http://www.creoz.co.uk/suresh/DSC00832.JPG

I had a lot of white smoke too and I disconnected my EGR pipe. Is there any problem if I do not plug it with a bolt and leave it as it is? Will it suck dust in and into the engine? It seems to be sucking in air.

thanks

[Col]

I had a lot of white smoke too and I disconnected my EGR pipe. Is there any problem if I do not plug it with a bolt and leave it as it is? Will it suck dust in and into the engine? It seems to be sucking in air.

thanks

You must plug the free end of the hose off as the vacuum as supplied by the tandem pump is also shared by the brake servo and turbo.

If you leave the end free you'll have no brake or boost.

[tyberwan]

Many people on this forum I have noticed mentioned black smoke before disconnecting the EGR. Mine produce a lot of WHITE smoke. Is this any different?

thanks

[debjohn]

hi just put a blank plate on exhaust end of link pipe from inlet to exhaust amd leave everything else in place simple as that, 10 minite job, ECU thinks all is working but no exhaust gasses get in inlet manifold

[All-rod]

Many people on this forum I have noticed mentioned black smoke before disconnecting the EGR. Mine produce a lot of WHITE smoke. Is this any different?

thanks

You might be getting white smoke because of blocked crankcase breather or for some other reason high pressure in crankcase pushing oil through seals burning it. in some cases smoke only appears when engine slightly overheats (like in traffic), possibly due to faulty temp sensor.