Egr and cooler replacement.

Raul a/3

Raul a/3

Active member
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I'm just about to start taking out the old egr and cooler. I have a brand new replacement and rear egr gasket. The front cooler pipe, I'm missing the gasket.
-Could I use a bit of exhaust paste on the old gasket?
-Also, the new egr, will it need adaptation after its all in?
Thank you all.
 
Right, I hit another problem. The new cooler comes without coolant breather take off, could I use it by blanking off the hose and bleed via vcds? All it does that helps bleed the egr cooler body.
 
Ok, egr and cooler it's in. I blanked the spare breather hose that suppose to connect to the cooler, but it's missing the hose connection. I started my second task, to remove the heater matrix and replace with a new one, before I fill the coolant and bleed the system. All the trim is off, glovebox off, but run out of daylight. Tomorrow, to be continued.
 
I think I'm on the home straight. The coolant bled, egr adapted, and new heater matrix in. No faults returned. A hell of a job that matrix, glovebox completely off, lower centre dash completely loose and pushed to the driver side. When puling the pipes off, I had to make a plastic fork tool and wedge it in the joint to release. On reattaching the new pipes to the new rad, that is a nightmare, bend, line up, silicone grease as the ally binds to each other, ended up tapping two 18mm spanners to a block of wood, and with pump pliers onto the spanners, like a press. Then put the clips back in. Very little room to wiggle the pipes home. All pressurised and heating restored. My old matrix was all bunged up. I suspect coolant types mixed up. Flushed the lot and used preston ready mix . Now putting the trims and glovebox back on. I hope I don't end with spare screws/bolts.
 
Mixed results. I had one trim screw left when I was done, I must missed one. But that, is the least of my worries. The heater matrix works. Atleast that job was a success. The warning light came back on, I think is the egr, will scan it tomorrow had enough today. I did the front pads as well, nice set of brembo's.
Maybe the adaptation of egr did not work properly. I will scan it and see what is the fault, clear it and do another adaptation from cold.
 
Update, new egr faulty, the motor is dead, the old works on vcds test. Swapping the old motor onto new egr now,
 
That didn't work, the motor assembly is different geometry, and the gear does not reach fully the plunger, meaning, it will not actuate. Cleaning the old egr and couple it to the new cooler, with a new gasket.
 
Phew, it's all in. Finally nailed it. Used the old egr after a clean, with the new cooler. Adaptation was successful, test drive did a regen as it warmed up, scanned again for codes, nil.
The egr cooler was the culprit for insufficient flow, causing the fault to come with insufficient regeneration core missing.
To summarise, if you see a cheap new egr with cooler on ebay, avoid, mine was a dud, just used the cooler from it. And make sure you buy spare gaskets, lucky I did.
 
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