Egr and egr cooler leak

[George_001]

I had the egr replaced under warranty and it seems to be leaking coolant. It’s going in tomorrow to get looked at but I’m worried as the work was done 4 months ago and worried I’ll get told it’s not their problem. I have narrowed it down to where it’s leaking but am unsure how the fitment is sealed on the photo I have circled where the coolant is coming from it’s a pipe on the cooler that fits in the back of the egr. Does anyone know the make up of these pipes or if there is some sort of gasket or o ring that stops the coolant leaking out

 

[Loz]

Who did the job? VW warrant work and new parts for 2 years.

 

[George_001]

Was van monster they gave me three months warranty with the van but it’s a genuine part

 

[Bigsidavies]

@George_001 did you get this sorted?
Mine had the egr flushed at VW in July and it seems to be leaking from the same place as yours is.

 

[George_001]

@George_001 did you get this sorted?
Mine had the egr flushed at VW in July and it seems to be leaking from the same place as yours is.

Yeh so the pipe that I circled in the photo was damaged during fitting the new egr and was leaking coolant they told me that it was a faulty part and to save the wait at vw they would change it for me. Whilst they played around they managed to split a coolant hose so the day after I got it back it dumped the lot. They then washed there hands with it and got vw to recover if and it cost van monster £450 for a £9 hose. So it got sorted and it only cost me inconvenience. Van monster did say that the joining pipe was a common fault so maybe you have cleared some debris that was plugging a hole. Cant really help much more than that sorry.

 

[DXX]

the pipe that I circled in the photo was damaged during fitting the new egr and was leaking coolant they told me that it was a faulty part

That looks like a transfer ferrule which probably has a soft seal, the sort of thing that should be replaced anyway if the EGR unit was removed.

 

[George_001]

That looks like a transfer ferrule which probably has a soft seal, the sort of thing that should be replaced anyway if the EGR unit was removed.

They told me it came with the egr and couldn’t be gotten separately but that could be just the story they told me to cover up other mistakes I didn’t hold out much hope for them wasn’t the best service I’ve had

 

[Bigsidavies]

They told me it came with the egr and couldn’t be gotten separately but that could be just the story they told me to cover up other mistakes I didn’t hold out much hope for them wasn’t the best service I’ve had

Thanks for the update. I’ve no doubt they did it when they did the egr flush.
They didn’t tighten up the bolts on the centre support that carries the prop shaft when they did the DMF.
It got spotted at Cosmic a couple of days later when they were fitting my diesel heater. One bolt missing and the other just about hanging in there.
Don’t have much faith in their competence. I’ll speak to them tomorrow.

 

[Bigsidavies]

Thanks for the update. I’ve no doubt they did it when they did the egr flush.
They didn’t tighten up the bolts on the centre support that carries the prop shaft when they did the DMF.
It got spotted at Cosmic a couple of days later when they were fitting my diesel heater. One bolt missing and the other just about hanging in there.
Don’t have much faith in their competence. I’ll speak to them tomorrow.

Anyway, quick update. It’s leaking from between the cooler and valve body which means a new egr unit. VW are adamant that the egr flush had nothing to do with it and I’m inclined to agree now I’ve researched what the flush involves.
Oh well.

 

[Handyman]

What does the flush involve as my van going in this week?

 

[Phil_j89]

A cleaning solution is flushed through the EGR / cooler, injected in on the exhaust side of the valve / cooler.
A pipe on the inlet side returns what is flushed through to a tank to be drained off.

100ml of the cleaning solution, to 900ml of water (works better if the water is hot)

Usually only requires one flush to lower the level in to tolerance. If under warranty, Vw will pay for two flushes to be carried out, any more and it requires an EGR cooler.

 

[LakesT6]

@Phil_j89 my old 204 Kombi had 7 flushes under warranty and one out of warranty through goodwill.

 

[Phil_j89]

@Phil_j89 my old 204 Kombi had 7 flushes under warranty and one out of warranty through goodwill.

It might have had seven flushes, but they’ll have been at different times. If it doesn’t work twice in a row (one after the other) then it’ll have a new cooler.
But like I say, most will lower the amount required from just one flush. So by vw’s standard, they are ok.

When you keep coming back for flushes on separate occasions, then they’re classed as separate claims.

 

[LakesT6]

@Phil_j89 I understand that the dealers hands are tied by VW on replacement of the cooler, but from a customer perspective it’s poor. VWCV UK make the customer jump through as many hoops as possible in the hope that they give up. Thankfully I got the last flush done under goodwill the week that I sold it.

 

[Handyman]

You did the right thing selling it. Mine going in on Thursday with P0401 fault. EGR was only flushed out July 2020.

Not sure whether good will, will prevail but I have full service history with the main dealer and a case file open with VWUK.

 

[LakesT6]

@Handyman I hope you get it sorted for free. I had FSH and a case manager from customer care. To be fair, my local dealer (Hadwins) were very good about it and did as much as they could for me.

 

[Handyman]

I dont have a problem paying for repairs but this thing with egr's is just something else. You actually do have a crystal ball on these occasions as you can pretty much guarantee the fault will re-occur and then have to go through the hoops again. You couldn't make it up!

 

[bruno73]

Ho fatto sostituire la valvola EGR in garanzia e sembra che perda liquido di raffreddamento. La porterò domani per farla controllare, ma sono preoccupato perché il lavoro è stato fatto 4 mesi fa e temo che mi diranno che non è un loro problema. Ho individuato il punto esatto della perdita, ma non sono sicuro di come sia sigillato il raccordo. Nella foto ho cerchiato il punto da cui prov2iene la perdita di liquido di raffreddamento: si tratta di un tubo sul radiatore che si innesta nella parte posteriore della valvola EGR. Qualcuno sa di che materiale sono fatti questi tubi o se esiste una guarnizione o un O-ring che impedisce la fuoriuscita del liquido di raffreddamento?

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Buongiorno a tutti , ho un problema di perdita di liquido allinterno del motore , il problema si è presentato dopo aver sosrituito la valvola egr , ho spia motore accesa e se non svito il tappo quando arresto il motore , al riavvio parte male e poi mi accede spia candelette e ricovery. La valvola e il radiatore egr sono uguali a questo in foto , allora io volevo bypassare il liquido evitando che entri nel radiatore , testando qualque giorno l'effetto ( partenze ok e livello liquido stabile ) ma non riesco a capire quale è la seconda entrata/ uscita , una è visibile a fianco del tubo di ricircolo gas , ma l'altra non capisco dove si trovi . È possibile indicare dove si trova su questo schema ?

Good morning everyone, I have a problem with fluid leaks inside the engine. The problem arose after replacing the EGR valve. The engine light comes on, and if I don't unscrew the cap when I stop the engine, when I restart it it starts poorly and then the glow plug and recovery light comes on. The EGR valve and radiator are the same as the one in the photo. I wanted to bypass the fluid, preventing it from entering the radiator, and test the effect a few days later (starts ok and fluid level stable). However, I can't figure out which is the second inlet/outlet. One is visible next to the gas recirculation pipe, but I don't understand where the other is. Is it possible to indicate where it is on this diagram?

 

[Bav]

Buongiorno a tutti , ho un problema di perdita di liquido allinterno del motore , il problema si è presentato dopo aver sosrituito la valvola egr , ho spia motore accesa e se non svito il tappo quando arresto il motore , al riavvio parte male e poi mi accede spia candelette e ricovery. La valvola e il radiatore egr sono uguali a questo in foto , allora io volevo bypassare il liquido evitando che entri nel radiatore , testando qualque giorno l'effetto ( partenze ok e livello liquido stabile ) ma non riesco a capire quale è la seconda entrata/ uscita , una è visibile a fianco del tubo di ricircolo gas , ma l'altra non capisco dove si trovi . È possibile indicare dove si trova su questo schema ?

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View attachment 328248

Ciao Bruno. Per favore, scrivi in inglese. Grazie.

 

[bruno73]

(Partenze ok e livello del liquido stabile) ma non riesco a capire a cosa serva il secondo ingresso/uscita, uno è visibile accanto al tubo di ricircolo del gas, ma l'altro non capisco dove si trova. È possibile indicarne la posizione su q
uesto schema?