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EGR Cleaning on Altea.

Discussion in 'Altea - includes XL and Freetrack' started by Toxic, Sep 29, 2008.

  1. loadswine

    loadswine loadswine

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    That Audi thread is mega useful, well done for finding that, I'm pretty sure that the mechanism inside the manifold flap is at the root of my error codes.
    Thank you.
     
  2. chrisash32

    chrisash32 Altea Driver

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    Funny this should be mentioned today! I am doing mine as we speak!!
    Literally just got my laptop sat on the engine looking at that audi sport website!

    Taking pics as a go anyway! Was going to post that same link up this afternoon.

    Just for the recorded i have taken my manifold part out and it is clearly fuber. The flap was jammed open. So i have taken the case off (which was full of oil - please remember this if you try it yourself) and you can clearly see that the cogs have mashed! Also the smell of a burnt out motor is VERY strong....

    So its off to euro tomorrow for a new one.. Was quoted £179 today for the part (did my home work just in case)

    If anyone is interested i will post up my pics and finding!

    Cheers!

    Chris
     
  3. loadswine

    loadswine loadswine

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    If the control mechanism is full of oil, no wonder the circuits are fubared and it keeps blowing fuses.
    Funny, with no fuse in and even showing that error code, it always starts first time now and runs a lot nicer. I'll have to get shot of that code though, so I guess I'll be buying a new flap unit as well.
    Rubbish design that it should fail so soon.
     
  4. chrisash32

    chrisash32 Altea Driver

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    very true. What miles are you on? I am 55k here...

    I must add over the past 2 weeks i have seen some amazing MPG.... Not sure if it is related or not... I guess we will have to see tomorrow.

    If mine goes well tomorrow and i can write a success story, I dont mind giving fellow Altea folk some assistance if they need any!

    Its quite a quick part to change. Just going to pack up outside and clean my EGR tonight.

    Who made the blanking plate on here? Just wondering what you used to do it? as i am thinking about making one myself.

    Cheers!

    Chris
     
  5. loadswine

    loadswine loadswine

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    I'm on 49k miles. I made a restrictor plate from sheet ally, seems to be okay, not noticed anything unusual apart from better fuel consumption, particularly on a run. Much better than its been for ages, possibly ever. i did pop a new maf in last month though, which might help a bit.
     
  6. chrisash32

    chrisash32 Altea Driver

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    funny you should mention the MAF as i did something to mine about the same time i started having problems with the manifold flap. So my MPG is probably MAF related.

    Have you got any pics of the plate that you made? If you wouldn't mind making another one i would be happy to chuck you some cash over on paypal if you want?
     
  7. loadswine

    loadswine loadswine

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    The plate is really simple, I'll see if I can pop it out and take a pic for you sometime this week.
    My maf had pretty much died I think. I tested by driving with it disconnected and it was no worse that way and may have been slightly better ,if anything. Got a remanufactured one for about £50 I think.
    It was an exchange uit, but no problem as its so easy to change, just popped it off before going into the shop, new one installed and away again in ten minutes.
     
  8. chrisash32

    chrisash32 Altea Driver

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    i did the silicone degrease trick on mine with the electrical connections. Worked an absolute treat. I was like you where even with the MAF disconnected the car was no different. Once i got the electrical contacts sorted it was all fine.

    Trying to think if I have anything about the house that i could make an EGR plate from.. Dont usually keep sheet steel about the house ;) lol
     
  9. CrispDust

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    chris - I used an old biscuit tin lid......
     
  10. chrisash32

    chrisash32 Altea Driver

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    nice one!

    what about the paint / print that's on it?
     
  11. CrispDust

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    wet and dry? Doesn't really matter anyway. It'll burn off or stay on depending on temp.
     
  12. chrisash32

    chrisash32 Altea Driver

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    cool, did you opt for the 4mm hole or complete blank off?
     
  13. chrisash32

    chrisash32 Altea Driver

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    Just to update, picked the new part up this morning! £143 from Euro! Bargain!!!!

    Will report back with fitting later!
     
  14. CrispDust

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    neither! I did go for 4 mm hole but kept getting cel light up. So when I fitted catch can I disconnected and plugged the vacuum pipe to EGR and put up with CEL!
     
  15. chrisash32

    chrisash32 Altea Driver

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    does it run any better without?
     
  16. CrispDust

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    Not sure if it makes any performance difference since its remapped anyway. I did it mainly to stop all the crap accumalating again after I cleaned the egr. Mine was caked up after only 24k miles!
     
  17. chrisash32

    chrisash32 Altea Driver

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    My EGR wasnt tooo bad... i have seen worse i know that!
    I will try restricting it.. Guess i will just have to keep making the hole gradually bigger until it stops putting the CEL on..
     
  18. JMH

    JMH Guest

    Egr / v157

    Hi All

    I had the yellow warning light a while back and bought VAGCOM to establish the fault which referred to V157 so I stripped the EGR and intake flap last weekend. The flap valve appears to be stuck open (although the engine shuts down fine) but if I switched on the ignition and then turned it off the flap was still open and there was a quiet high pitched whine as though the valve was trying to close. Should the flap be in the closed position with the ignition off, I guess so? So I suspect the flap valve needs replacing.

    Among the other things which I don't understand is how the EGR works. How does engine management system know to put the warning light on if you blank off the EGR inlet or if it doesn't open? From previous comments I guess there must be some sort of sensor/feedback? Mine wasn't too badly gunged up at 37K but I cleaned it up ok and blanked off the vacuum pipe to the EGR valve to stop it operating. I tested the EGR (by sucking) and it works ok.

    The air inlet pipe to the EGR valve was quite "oily" which I guess comes from the turbo - is this normal? I was expecting the pipework to be bone dry but I don't have any previous experience with turbos.

    John
    2005 2.0TDI Altea Sport
     
  19. chrisash32

    chrisash32 Altea Driver

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    the flap on mine was stuck open. Has yours popped a fuse at all?

    Once the flap has closed on engine shut down, it re-opens again about 30sec after you turn the car off.
    The cogs had crashed in mine meaning the mechanism had jammed.

    Drop me a PM of you need any more help diagnosing.

    Cheers!
    Chris
     
  20. CrispDust

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    JMH - heres what happens - air gets sucked in through the air filter by turbo/engine induction vacuum. It then picks up oil/vapour that is pushed out of the engine crankcase by the positive pressure of pistons gong up and down and oil pump. This oil is carried along the whole air inlet system (VERY long on a BKD engine), thru intercooler and is then burnt off in engine. Unfortunately ALOT of it just hangs around in the air inlet tubing/intercooler. especially if you don't regularly open up the old girl and coats the pipework. You will see it ooze from inlet tube joints when these start to go (poor design). Obviousley the oil rich air passes thru the EGR. Here it mixes with the soot recycled back from exhust creating a lovely oil/crap/soot mix which clogs up egr and eventually the inlaet manifold. It looks as though the oil drips back down into antishudder/shut off flap mechansim too.
    The ecu can detect when the egr is not letting enough gas thru as there is a sensor/regulator in the heat exchanger mechanism as the exhaust gas is tapped off the exhaust pipe. Old 1.9 engines can be vagcom'd to reduce the egr action. 2.0tdi can't.
     

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