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I had an egr pipe crack but where there was no way to see the crack. I could hear a loud squeek. So to eliminate or identify the egr system as the source i blocked off at the intake and at the exhaust manafold of the egr system. The squeek went away. So i knew it was the egr system. Then i...

The copper is about the same thickness as a soda can. And could probably be made with a pair of stirdy scissors. Leave a tab to pull it out when testing is finished. Im holding it by the tab in the pictures.

So all that needs to be done is cut a peace of copper in the shape of an egr gasket then trim it so it can be slid in with only loosening the egr tube bolts. https://forums.tdiclub.com/index.php?media/20250223_161938-jpg.163208/ https://forums.tdiclub.com/index.php?media/20250223_161933-jpg.163209/

Sealing plate for testing egr tubes for leaks

Had an egr tube crack a while back and could hear a wistle but could not see where it was coming from. So i came up with a way to test where the leak was coming from without removing the egr components for inspection.

Runs a few degrees cooler now and when it gets hotter from climbing grades it cools down faster.

Turned out the thermostat was lazy. And my fuel temp sensor was off at operating temps. Swaped a vw brand thermostat in and a acurate fuel temp sensor. Now my temps are a bit lower and my miligrams per stroke fuel are lower. My mpg is improved. I did test both thermostats and the vw brand one...

Fixed it. Was a series of problems. Fuel tem sensor was off. But only when warmed up. Thermostat was lazy. Was a mahle or how ever you spell that. Swapped it for the vw brand thermostat and temps became better. Each one of these made the car run better. And the shudder became less. I had a...

I will go through all the fan tests in the order of that trouble shooting guide and get back to you. I did them all yesterday thoug a bit diffrent order. I suspect something is up with ether the high or low fan setting through the fan realy when the fan heat switch plug at the radiator is jumped.

I was told a heathy temp was 80-90c

Oh also checked all the fan related fuses and they are all fine. No blown fuses.

Vheicle 2005 vw jetta wagon 1.9 tdi pd BEW. So i noticed my coolant temps are climbing higher than they should using vcds. They climb as high as 99c on a long steep grade. I went to test my radiator fans and the fan relay box. First test ignition on engine not running ac button on and...

Up date. So it was not the egr or anti shudder valve i cleaned both and put them back one then the other. The shudder was still there. I then unpluged only the egr valve and the shudde went away and fuel milage improved some. This made me think whats the only part left for me to inspect. Well...

I know this is an old thread. I would recomend checking your in tank lift pump for proper function. You should be able to hear it gurgle alittle when you turn your key on but not all the way to the starter position. You can also detach the outlet line from the fuel filter and put it into a cup...

Oh you are talking about on an alh or ealier tdi. Those have vaccume operated egr vlaves and shudder valves. This is a BEW tdi. So it has an electronically activated ASV and EGR valve. But you are still rite about the ASV could be the culprit or part of the issue. My suspision is the EGR valve...

I had previously swaped in an egr valve i pulled from a working car. But on the sugestion of a mechanic I unpluged it. And now the shudder and boost drop have gon away. Sence i swapped the egr valve with one i cleand from a working car without this issue im suspecting it is either sticking or...

I sent you a log with the torsion value still at 4.9. I noticed the group four injection start specified value jumps close to the time that the shudder happens. It also jumps with the torsion value set to .5.

Thanks for the responses. I still found a bunch of usefull threads to read with that google shearch tool and setting the tosrion to 4.9 was informative. And really did seem to improve the powerband range. I set it back to .5. I also had forgotten how little a movement on the cam gear can effect...