EGR flexi-pipe: Exhaust Fumes In Cab, Hissing From Engine Bay.

Looking at the access its a pig of a job! I have the 204 engine so access isn't so easy
Took me a whole day to do. Still not sure the bolts are quite tight enough but seems to be ok. My hands took a right beating. There’s something back there a bit lower down too that looked like the oil filter cap on my 5.1 and I’m hoping to god it’s not!!
 
mines just gone . . . well its been leaking for a while. MY18 204 DSG 36k miles. (within warranty - just)

The AA guy failing to diagnose it. (VW Assist callout, asked for VW guy but got the yellow van guy =[ )

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The VW assist correctly diagnosing it: (VW Assist callout)

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My pipe as is now.

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New one to be fitted in a couple of days hopefully. (VW Assist callout - return to fix with parts)


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ill update when its done.

Edit:

He called this morning to say the local TPS was out of stock... part ordered and due for collection over the next day or so.


edit: parts are in apparently - job to be done mobile today.

edit:

all done, the VW Assist guy had it done in 15mins with me chatting to him on the driveway whilst doing it.

no special tools . . . just a 1/4 inch small ratchet,

with a small 1/4 inch extension bar,

and the splined bit for the bolt.

he just took out all four bolts one at a time . . . just feeling blind.

then took out the old, and swapped for the new.

again replacing the bolts one at a time.

one small tip was that he used electrical tape to tape the bolt into the bit, when refitting them - to stop the bolt from falling off.



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this is the old and new unit:

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common problem as he had a second faulty one on the van . . . .


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he done it all ftrom the topside just reaching down . .

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and the paperwork for it . . .

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this is how he reached it.


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... Thanks VW Assist - fixed it again =]

well worth the VW roadside assist fee . . . . i think ill look at paying for the extra two years callout fee . .

i think @Loz took this option?


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How did you get such close decent photos? I can't even see the pipe properly, never mind get access to the bolts.
with a LED work light and pushing the phone down there to take the pics blind. . . i must admit its tricky.

an even harder job if its a DSG apparently, according to the VW Assist guy. (DSG oil cooler in the way etc)

@Tourershine has done his himself - see earlier in thread.
 
I’ve got the 150 DSG and I reckon it was the hardest job I’ve done by far. Still not sure I’ve got the bolts done up tight enough, but it’s all I could do with the clearance for tools and hands.
 
My 204 manual (2017) rear EGR pipe just went too, only 18,000 miles but just out of warranty...


I’ve filed a safety report to the DVLA from the link earlier in this thread. It’s a safety issue and should be a recall.

Trying to find a stockist in the Plymouth area for tomorrow, do TPS sell to trade only?
 
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@deftonkorn - just watched those two vids with the password . . . great - love it . . (old pipe and new pipe)

whats the platform? - where is the vid hosted? - i like that and would like to give it a try?
 
VW have agreed that they will change the pipe for £65 as a matter of good will.

bear this in mind if you are being charged £150+ for parts (pipe gasket and bolts)

hope this info helps someone
 
I would like to get my hands on a split one to see if a proper flexible duct can be used to replace the stupid corrugated offering. Anyone local to me in Suffolk got one that can be donated for research? My idea is to weld/braze a longer length of Polylock in place of the tube and corrugations.
 
I would like to get my hands on a split one to see if a proper flexible duct can be used to replace the stupid corrugated offering. Anyone local to me in Suffolk got one that can be donated for research? My idea is to weld/braze a longer length of Polylock in place of the tube and corrugations.
The revised replacement part is much better.
 
It may well be but it doesn't satisfy my desire!


the guy let me keep mine . . .








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you can see the fatigue crack here:


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its a very small pipe . . .


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