Hey guys I just had a typical hissing boost/vacuum leak from the EGR cooler diverter valve. Finally figured out an easy $5 fix that works 100% and its easier to do then actually replacing the whole $350 EGR cooler system and you can do it all without removing anything but one bolt.
I tried thermal woven gasket material from ovens, (didn't work) see here:
http://forums.tdiclub.com/showthread.php?p=4284261#post4284261
I also tried putting just coupe of perfect sized washers OD 17mm, ID 6mm, but still had hissing (less tho).
$5 FIX THAT DID WORK:
Quiksteel from Walmart $4.27+tax (rated for 500F) and I made a small metal part that goes under one of the bolts so that it holds all the Quiksteel pushed inside. Took about 30 minutes to get the metal part just the right size but anyone can make one. All you need is a drill, hacksaw and a metal file.
You could use something that is rated for much more then 500F, but keep in mind that you need to use something that is like a putty so that you can easily work it into the hole, if the glue/epoxy you end up using is too runny you won't be able to get it into the hole (please post below if you find any putty like epoxy that is rested higher then quiksteel)...
IMPORTANT NOTES:
Mix the 2 part guiksteel really good but fast, it hardens really really fast. I CAN'T stress this enough. On my first try it hardened on me and I only filled half the hole so I had to get all the stuff out which was super super hard once this stuff hardens. SO MIX FAST but well (60 sec max) then fill the hole asap. Also it helps to have the metal part made already as you can use it to push the quiksteel up into the hole... Doesn't look great but works great, I'll update everyone if this doesn't last long as I'm not sure 500F rating is good enough.
PS I didn't use the spring that usually holds the original gasket and shaft.
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I tried thermal woven gasket material from ovens, (didn't work) see here:
http://forums.tdiclub.com/showthread.php?p=4284261#post4284261
I also tried putting just coupe of perfect sized washers OD 17mm, ID 6mm, but still had hissing (less tho).
$5 FIX THAT DID WORK:
Quiksteel from Walmart $4.27+tax (rated for 500F) and I made a small metal part that goes under one of the bolts so that it holds all the Quiksteel pushed inside. Took about 30 minutes to get the metal part just the right size but anyone can make one. All you need is a drill, hacksaw and a metal file.
You could use something that is rated for much more then 500F, but keep in mind that you need to use something that is like a putty so that you can easily work it into the hole, if the glue/epoxy you end up using is too runny you won't be able to get it into the hole (please post below if you find any putty like epoxy that is rested higher then quiksteel)...
IMPORTANT NOTES:
Mix the 2 part guiksteel really good but fast, it hardens really really fast. I CAN'T stress this enough. On my first try it hardened on me and I only filled half the hole so I had to get all the stuff out which was super super hard once this stuff hardens. SO MIX FAST but well (60 sec max) then fill the hole asap. Also it helps to have the metal part made already as you can use it to push the quiksteel up into the hole... Doesn't look great but works great, I'll update everyone if this doesn't last long as I'm not sure 500F rating is good enough.
PS I didn't use the spring that usually holds the original gasket and shaft.
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