EGR valve removal/clean - 1.9PD TDI
Discussion
Evening all,
I've got a 1.9tdi 100bhp lump in a 56 plate Polo. Having recently completed my first ever DIY cambelt/waterpump change and feeling rather pleased with myself, I thought taking the EGR valve off for a clean would be "easy." However, I can't get the poxy thing off. Compared to youtube DIY guides for the VAG 1.9tdi such as this https://www.youtube.com/watch?v=l_aL3xciHZI, my EGR valve assembly seems "longer." As a result, access is extremely tight, I seemingly cannot get to one the two bolts which hold the EGR pipe underneath. I've marked the visible one with a red arrow in the pics below. I can't get a hex socket onto it as there is a bracket/manifold casing immediately underneath which blocks access. I loosened off the plastic ducting at the back so I can just about get access onto the second bolt (not shown in the pics below) at the back. I need to remove the EGR pipe in order to get access to the third and final bolt which secures the EGR valve onto the manifold. In the youtube video above, he has a lot more space to work with and easily gets a ratchet onto the two bolts securing the EGR pipe. This is impossible to do on mine; looking closely my EGR assembly is definitely slightly longer. Does anyone know what the "trick" to getting this off is? I know a lot of people routinely blank the EGR off or clean it as part of routine maintenance, I'd be very grateful for any help.
Cheers
I've got a 1.9tdi 100bhp lump in a 56 plate Polo. Having recently completed my first ever DIY cambelt/waterpump change and feeling rather pleased with myself, I thought taking the EGR valve off for a clean would be "easy." However, I can't get the poxy thing off. Compared to youtube DIY guides for the VAG 1.9tdi such as this https://www.youtube.com/watch?v=l_aL3xciHZI, my EGR valve assembly seems "longer." As a result, access is extremely tight, I seemingly cannot get to one the two bolts which hold the EGR pipe underneath. I've marked the visible one with a red arrow in the pics below. I can't get a hex socket onto it as there is a bracket/manifold casing immediately underneath which blocks access. I loosened off the plastic ducting at the back so I can just about get access onto the second bolt (not shown in the pics below) at the back. I need to remove the EGR pipe in order to get access to the third and final bolt which secures the EGR valve onto the manifold. In the youtube video above, he has a lot more space to work with and easily gets a ratchet onto the two bolts securing the EGR pipe. This is impossible to do on mine; looking closely my EGR assembly is definitely slightly longer. Does anyone know what the "trick" to getting this off is? I know a lot of people routinely blank the EGR off or clean it as part of routine maintenance, I'd be very grateful for any help.
Cheers
Had the same problem with my Leon Mk 1. After much swearing and skinning of knuckles, I gave up and got a garage to do it.
You could maybe just get an straight-through EGR delete pipe fitted to avoid any future issues, although this also means you lose the anti-shudder / shut-off valve in the inlet so will get a little more shake when the engine is turned off.
I also had the EGR flow turned down to a minimum in VCDS to delay any future clogging. There's a guide somewhere on seatcupra.net.
Alternatively you could try blanking off the EGR take-off pipe at the exhaust manifold, but on some engines this brings the engine warning light on, unless a small hole is left in the blanking plate.
You could maybe just get an straight-through EGR delete pipe fitted to avoid any future issues, although this also means you lose the anti-shudder / shut-off valve in the inlet so will get a little more shake when the engine is turned off.
I also had the EGR flow turned down to a minimum in VCDS to delay any future clogging. There's a guide somewhere on seatcupra.net.
Alternatively you could try blanking off the EGR take-off pipe at the exhaust manifold, but on some engines this brings the engine warning light on, unless a small hole is left in the blanking plate.
The bit with the flap is the anti shudder valve (ASV), if it's the same as my 2007 Ibiza FR it should come apart from the EGR and give you a little more room.
Not 100% sure if it applies to the PD100 but for the PD130 in the Ibiza/Fabia/Polo the newer versions that have the separate EGR and ASV and they do make a blanking piece for just the EGR section.
Not 100% sure if it applies to the PD100 but for the PD130 in the Ibiza/Fabia/Polo the newer versions that have the separate EGR and ASV and they do make a blanking piece for just the EGR section.
Thanks gents; I will have another go when I next get a free afternoon.
I know it doesn't look too "bad" but I would rather give it a good clean now before it starts looking like the inside of an old chimney.
Cheers for the help
I know it doesn't look too "bad" but I would rather give it a good clean now before it starts looking like the inside of an old chimney.
FRMATT said:
The bit with the flap is the anti shudder valve (ASV), if it's the same as my 2007 Ibiza FR it should come apart from the EGR and give you a little more room.
Not 100% sure if it applies to the PD100 but for the PD130 in the Ibiza/Fabia/Polo the newer versions that have the separate EGR and ASV and they do make a blanking piece for just the EGR section.
I didn't realise that, I thought the flap/butterfly thing was the EGR valve? Just looked through that youtube vid again and a few others, they all seem to show the flap when pointing out the crap inside, but I guess that's because they haven't separated the EGR valve from the ASV. I will try and see if I can separate the two in situ before trying to remove the EGR valve; if I can do that it will make access a lot easier Not 100% sure if it applies to the PD100 but for the PD130 in the Ibiza/Fabia/Polo the newer versions that have the separate EGR and ASV and they do make a blanking piece for just the EGR section.
Cheers for the help
Gassing Station | Audi, Seat, Skoda & VW | Top of Page | What's New | My Stuff