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  1. #1
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    Do 2.0TDI BKD EGR Coolers Really Leak???

    I have a slow coolant leak from my recently purchased 2.0TDI 140 BKD engined 2004 Sport. I have put some dye in the coolant (detectable with an infrared lamp), but have not tracked down any external leak so far. Checked inside for a faulty heater matrix, and its all bone dry.

    I have spoken to the local Audi garage, who say its probably either a suspect EGR cooler, or head. They suggested replacing the EGR cooler first, then the head if the leak still persists. They wanted 150.00 to carry out a overnight pressure test, so you can imagine my response to that….

    Question is, has anyone ever seen, or found evidence that the EGR coolers do leak. I'd rather try and replace the cooler first, and then think about a porous cylinder head if replacing the cooler does not cure the coolant leak. Third option is a dose of K Seal, but I'd rather have the leak fixed, rather than just masking the issue with a temporary fix.

    Apart from this, I'm loving my A3.......


    Regards

    Antony

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  3. #2
    devonmikeyboy's Avatar
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    Never heard of the EGR leaking myself but i guess it`s possible. Get a secondhand cooler and fit it and try i guess.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

  4. #3
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    Quote Originally Posted by Tonyc View Post
    I have a slow coolant leak from my recently purchased 2.0TDI 140 BKD engined 2004 Sport. I have put some dye in the coolant (detectable with an infrared lamp), but have not tracked down any external leak so far. Checked inside for a faulty heater matrix, and its all bone dry.

    I have spoken to the local Audi garage, who say its probably either a suspect EGR cooler, or head. They suggested replacing the EGR cooler first, then the head if the leak still persists. They wanted 150.00 to carry out a overnight pressure test, so you can imagine my response to that….

    Question is, has anyone ever seen, or found evidence that the EGR coolers do leak. I'd rather try and replace the cooler first, and then think about a porous cylinder head if replacing the cooler does not cure the coolant leak. Third option is a dose of K Seal, but I'd rather have the leak fixed, rather than just masking the issue with a temporary fix.

    Apart from this, I'm loving my A3.......


    Regards

    Antony
    Did you get this sorted? What was the fix?

    I've had a 53 plate 2.0TDI (BKD engine) for a month and having the 'coolant issue' (losing, but no leaks, no mayo-effect oil etc). I'm 99.9% certain it's this so called EGR coolers / porous cylinder head problem. However, reading through various articles on the web, like you, I'm unconvinced replacing EGR coolers will do anything as nearly all responses I've seen have had no success and had to replace the cyl head before, hey presto, problem solved.

    Not a hope in hell I'll be paying Audi a bean, so any advice you can pass on would be great.

    Has anybody sourced a cheap, quality, after-market cylinder head for these models. How much would an independant charge to fit? Should I definitely bypass the cost of replacing EGRs?

    Thanks
    Kevin

  5. #4
    NHN
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    TBH I have to agree with Mikey, I've not heard of any issues of the cooler leaking, guessing you checked behind the cooler as its nicely hidden at rear of engine top right, I've gotta take mine of to check its not clogged tbh on my missus SB as removed egr/IMF & gave them a good clean as were caked, might do intake soon aswell as thats caked aswell.

    Mikey on a side note, any ideas on a crappy start 1st thing & its not exactly cold atm, changed to new starter of mine but still same, every subsequent start is pukka, strange, next doing fuel filter/pump as got spare, doing my nut in as I also think this maybe the hesitation issue aswell maybe fuel line problem or injector.

    Oh whilst on subject you still got bkd inbjectors spare as Jordans car has an issue we suspect is injector.

    Thanks in advance & sorry if OT.

    OEM RETROFITS - CRUISE CONTROL - SAT NAV - BLUETOOTH - AMI - HEADLIGHT SYSTEMS

    PARKING SYSTEMS - DIAGNOSTICS - FAULT FINDING - BODYWORK - PAINTWORK

  6. #5
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    Quote Originally Posted by kstaylor99 View Post
    Has anybody sourced a cheap, quality, after-market cylinder head for these models. How much would an independant charge to fit? Should I definitely bypass the cost of replacing EGRs?

    Thanks
    Kevin
    I have a few secondhand BKD heads laying about plus a flowed and ported performance head. PM me if you seriously want a head.

    Quote Originally Posted by NHN View Post

    Mikey on a side note, any ideas on a crappy start 1st thing & its not exactly cold atm, changed to new starter of mine but still same, every subsequent start is pukka, strange, next doing fuel filter/pump as got spare, doing my nut in as I also think this maybe the hesitation issue aswell maybe fuel line problem or injector.

    Oh whilst on subject you still got bkd inbjectors spare as Jordans car has an issue we suspect is injector.

    Thanks in advance & sorry if OT.
    As for a crappy start can be one of many things as you probably know yourself. Usual suspects are leaking injector or fuel pump/filter problems but as it`s every other start very strange. I still have some standard injectors about and a nice set of uprated injectors if somebody should want some extra power.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

  7. #6
    NHN
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    Quote Originally Posted by devonmikeyboy View Post
    PM me if you seriously want a head.
    Come again, lmfao.

    Quote Originally Posted by devonmikeyboy View Post
    As for a crappy start can be one of many things as you probably know yourself. Usual suspects are leaking injector or fuel pump/filter problems but as it`s every other start very strange. I still have some standard injectors about and a nice set of uprated injectors if somebody should want some extra power.
    Yeah will attack fuel supply next mate as maybe its to do with initial supply of fuel thats causing an issue, I will do filter tomorrow, maybe pump later aswell.

    Its weird the hesitation, you put your foot down even to the floor & there is nothing, no revving just idle still, then all of a sudden the revs pickup, when pulling from a junction is slightly worrying as you think ok pulling away then nothing there then it decides to do something, royal PITA.

    Map hasnt done anything to change it either as was done last week.

    OEM RETROFITS - CRUISE CONTROL - SAT NAV - BLUETOOTH - AMI - HEADLIGHT SYSTEMS

    PARKING SYSTEMS - DIAGNOSTICS - FAULT FINDING - BODYWORK - PAINTWORK

  8. #7
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    Hesitation :Have you checked behind the accelerator that the Electronic Control Module is plugged together properly?
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

  9. #8
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    I had a leak after picking my car up, it turned out to be the radiator leaking

    the dealers charged Ł75 for a pressure test and total bill came to just under Ł500 - so don't use main dealers

    if it's your rad then after driving for a while, leave it parked up over a nice clean dry area and you should see a wet patch after a while - it's a common problem with A3s and mk5 Golfs where the rads corrode in the bottom corners
    2.0 TDi 140 S-Line With - S3 Vents l S3 Alloy Pedals l S3 Gearknob I Aero Rear Wiper l X-Treme Bulbs l 09 Rear Lights l Custom Floormats l 18" TTS reps l LCR Splitter I Facelift Stereo

  10. #9
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    Quote Originally Posted by devonmikeyboy View Post
    Hesitation :Have you checked behind the accelerator that the Electronic Control Module is plugged together properly?
    Think its pointing to mechatronic atm, update when I know.

    OEM RETROFITS - CRUISE CONTROL - SAT NAV - BLUETOOTH - AMI - HEADLIGHT SYSTEMS

    PARKING SYSTEMS - DIAGNOSTICS - FAULT FINDING - BODYWORK - PAINTWORK

 

 

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