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Old July 24th, 2006, 17:55   #1
2002 Harv
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TDI(s): 2004 TDI PD
Default EGR Cooler/valve

Ok, I have had the slight coolent dissapearence since i bought my 04 PD Jetta wagon. I figured I could live with the problem for a little while till I felt like taking the hit and buying the part (the egr cooler) and do the install. Yesterday, while we were driving to my Mom's house (500mi) The check engine (check emitions) light came on. Since it was a Sunday and we were far from home, we trudged on. When I got to Mass. I had my friend scan the car for codes. We got (insufficient egr flow) from his Launch scan tool. He reset the ecu and the light came back on in about 10 miles.
So my question is this.
Is the EGR cooler and the EGR valve the same part?
I don't think there is any harm in driving the car till I do the job considering the car runs normally and the temp gauge is normal at 190.

John
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Old July 24th, 2006, 20:33   #2
Fortuna Wolf
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There's no great harm to be had, just some coolant migration into the motor oil. Its a bad EGR cooler on 2004 PDs. The cooler has been redesigned but failure is very common.
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Old July 25th, 2006, 06:58   #3
PDJetta
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The coolant leak is into the exhaust side. A little coolant may get into the oil, if it does, its not much. My guess is that the leak caused the coolant to evaporate in the cooler, gumming it up, reducing the exhaust flow through it, tripping the CEL after the Mass Air Flow (MAF) sensor detected more air flow through it (since less flow was through the EGR valve).

No harm whatsoever driving the car with the CEL on and too little EGR flow (actually, its better for the car), but the leaky EGR cooler is not.

The EGR cooler and EGR valve are two different parts. The cooler cools exhaust before it reaches the valve, which meters the exhaust into the intake manifold, in conjunction with the electric throttle plate.

--Nate
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Old July 25th, 2006, 07:46   #4
2002 Harv
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So I'm guessing that I need a new cooler and new EGR valve. Anyone think the EGR valve is cleanable? The car has 57K on it. When I'm ordering the parts, should I get all the gaskets for the intake manefold and clean that too?

John
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Old July 25th, 2006, 08:21   #5
tongsli
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You probably just need to clean the EGR valve and intake manifold. See if that helps. You can always change the EGR cooler since it's a separate item that sits behind the intake manifold.
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Old July 25th, 2006, 09:24   #6
2002 Harv
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So the EGR cooler bolts to the EGR valve and that bolts to the manefold.

Ok, so I'm gonna look for the best price on the EGR cooler and order all the related gaskets to clean the intake. What else should I buy/watch out for/repair while I'm at it?

John
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Old July 25th, 2006, 12:03   #7
Fortuna Wolf
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No, the EGR cooler bolts to the EGR flap which is connected to two tubes, one to the exhaust manifold the other to the intake manifold. The EGR valve is bolted onto the intake manifold. The EGR valve and intake can be cleaned, but the EGR cooler is broken. You can try to get it replaced under warranty but YMMV.
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Old July 26th, 2006, 16:28   #8
2002 Harv
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Quote:
Originally Posted by Fortuna Wolf
You can try to get it replaced under warranty but YMMV.
Yea, the local dealer says it's not part ot the engine. Go fig. I would assume that they don't consider the water pump and alternator as part of the engine too. My Jetta has 58K on it and they would cover it if the car was still under the basic warranty which it is not.

John
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Old July 26th, 2006, 20:09   #9
Fortuna Wolf
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The dealership here thinks that 60k is the magic number.
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Old July 27th, 2006, 06:05   #10
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I think the powertrain is defined as the block and head all internals and the transaxle. Nothing bolt on is part of the powertrain. It may include the drive axles too. So the WP and alternator are not included. Not my definition, VW's. The owner's manual may say, but like Fortuna Wolf says, it can vary by dealer, since its so confusing to begin with.

--Nate
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Old July 27th, 2006, 07:42   #11
2002 Harv
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No doubt! Kinda piss poor attitude from VWOA.

Well. Gonna dive into this job. Maybe I should just delete it and put in a Roketchip?

John
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Old July 27th, 2006, 21:38   #12
Kirtwell
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Quote:
Originally Posted by 2002 Harv
No doubt! Kinda piss poor attitude from VWOA.

Well. Gonna dive into this job. Maybe I should just delete it and put in a Roketchip?

John

My EGR is deleted.....gone!!! Just talked to Rocketchip and I'm sending it off to get it reprogrammed. Can't wait
My 04 just passed 60K and the dealer said NO WAY are we covering that...so I took it off...made some nice caps to cover the intake and the exhaust....professionally machined

If anyone needs a set..Hollar and I'll send them to you for the cost of shipping...I'll probably make some extras for my TDI buddies.
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Old August 2nd, 2006, 17:02   #13
2002 Harv
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So I had talked to the dealer about my EGR cooler and they basicly said it's not going to be coverd under any warenty. So I have just been living with it. Last week we went to Mass. and back (500mi each way) Durring the trip I got the check engine light (04 PD). My friend Jeff read the code, and sure enough it was low EGR flow.
I started pricing EGR coolers last week. I went into the dealer to pickup some touchup paint I had ordered and asked them how much one was for giggles. He cut me a brake and quoted me around 350$. He said I should check with service to see if they would warrenty it. I walked in and once again pled my case. This time they said they should be able to warrenty it. I said great, let's do it. They called me today and said VW will not cover it and the part is 450. I stayed calm and told them I was quoted 350 for the part when I was about to do it myself. They changed the price and since I'm sick this week I said go ahead and do it.
I called VW to complane about the switch and the lack of coverage and the dealer saying they could "probably" get it covered. I do all my own work and would have done this job too.
I told VW this is heavly influencing our decision to by an 08 Passat TDi or Tourag TDi

John
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Old August 2nd, 2006, 19:58   #14
Fortuna Wolf
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2002 Harv, the part is $307 on Impex. Shop around damnit! I'll sell you one for $375!
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2002 Jetta Sedan ALH-01M: 2 um Cat FF, Wingnut-3 CCV filter, polyurethane fuel lines, 5 brake light mod, Ventectomy, Polysiloxane vacuum tubing, Pioneer DEH-3800MP w/ KFC-1389ie, Panzer Plate, EGT+Boost+Oil Temp Gauges, Boost Valve, KERMA Line Pressure Mod, LED Lighting, HC-12a refrigerant, Optima 75/35 AGM, .187 nozzles, Hawk HPS pads.
Coming Soon: ESP retrofit, Custom Greasecar.

Wish List: Tow Bar, DSG or CVT transmission, or even a 5 speed manual. To hit 42+ mpg

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Old August 2nd, 2006, 20:09   #15
roadhard1960
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My egr was goofed up when I cleaned my intake. No errors before I removed the intake but I do not know if I got solvent into the rubber gasket or something else. When I attached the MityVac pump to it, I could not get the valve to stroke. I put the car back together and it started with the engine light. VagCom showed the same error as yours. I will buy a new egr sometime.
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