B7 2.0 TDi EGR cooler pipe blown off

[markie1970]

Hi guys I have just driven my a4 2.0 TDi b7 and when I put my foot down there was a loud pop and the exhaust system then sounded like a tractor!. I have found the problem to be a hose blown off at its flange weld on the EGR cooler as per the picture below:


This is not my egr cooler but a pic of one I found when searching online. Can I drive the car safely to a garage? The pressure required to do this must have been large - is something else at fault which may of caused it? I have heard mentioned of a EGR removal - is this wise or feasible? What is the best way ahead?

Any help greatly appreciated - thanks in advance

 

[Liam198Three]

Hi guys I have just driven my a4 2.0 TDi b7 and when I put my foot down there was a loud pop and the exhaust system then sounded like a tractor!. I have found the problem to be a hose blown off at its flange weld on the EGR cooler as per the picture below:


This is not my egr cooler but a pic of one I found when searching online. Can I drive the car safely to a garage? The pressure required to do this must have been large - is something else at fault which may of caused it? I have heard mentioned of a EGR removal - is this wise or feasible? What is the best way ahead?

Any help greatly appreciated - thanks in advance

Hi there, just found this post - exactly the same has happened to my recently purchased A4 B7 TDI SLine 140 this morning.....what was the outcome/ remedy / cost etc?

 

[Liam198Three]

Hi there, just found this post whilst doing some research online. Dont want to highjack the thread, but im guessing since August you are on the other side of this issue! - Exactly the same has happened to my recently purchased A4 B7 TDI SLine 140 this morning. I had literally only just pulled out of my drive when it went, and have driven no further than 200 metres to turn the car around and return home at a snails pace so hopefully no other supplementary damage caused. What was the outcome/ remedy / cost etc to get yours sorted? Car was purchased 4 weeks ago, and whilst i thought id done my research (despite the obvious gamble in buying a B7 with a BLB engine), i went for a private sale, so i have no warranty to fall back on. Fearing the worst, particularly given i still owe money borrowed for the car and christmas is fast approaching!!

Any assistance/ advice much appreciated from anyone!! I am reasonably mechanically minded, and have worked on all my previous cars, however this is my first VAG Turbo Diesel powered car.

Thanks in advance.

 

[DieselJake]

Blank the egr and chuck the rest in the bin.

 

[Cyrix]

Same happend to me, I saw the crack when I viewed the car and incorrectly assumed the pipe would be replaceable like the majority of EGR coolers, how wrong was I.

EGR cooler, 2x gaskets, 2x copper nuts plus coolant will probably stand you at £340 from TPS, took me an hour to change in the dark on my drive. You will need both Spline and Torx bits to remove the cooler.

Removal would be the better long term fix - blanking plates are about £15 plus the EGR function removal from the ECU at say £75-100 from one of the many TDI tuning companies. I would have done this but I had a 600 mile trip the next day and couldn't really afford to mess around.

 

[Liam198Three]

Thanks for the replies guys.

I had wondered how crucial the EGR system actual was to the running of the car. Are there any negative consequences of removing and mapping out the the EGR system? I was potentially looking at having the car mapped anyway for increased performance and economy does this usually involve EGR removal anyway?

I have done a bit of phoning round today and been quoted around the £400 mark (parts and fitting) by two local independant Audi specialists. However if i could get it removed, blanked off and re-mapped for similar money with no detrimental effects then that could be a better option.

A mechanic friend has also suggested/ offered to remove it, weld the flange back on and re-fit as a cheaper/ shorter term fix to get the car back on the road while i get some money together and decide which route to go down longer term. Anyone tried this or any thoughts on whether this is a good idea?

 

[harleymonster]

does any one have a broken cooler I can buy the valve off the end

 

[D2NY G]

i had this problem, sized it back up marked it and braised it, then re fitted

 

[jwhat]

This just happened mine, did the brazing stand up or did it break again? €380 +VAT for a new one is bit much.

 

[D2NY G]

This just happened mine, did the brazing stand up or did it break again? €380 +VAT for a new one is bit much.

still working fine mate, happened well over 2 years ago now

 

[jwhat]

still working fine mate, happened well over 2 years ago now

I've sent mine off to get brazed, couldn't find a second hand one anywhere and need the car for the weekend. hopefully it will hold out like your.

 

[D2NY G]

I've sent mine off to get brazed, couldn't find a second hand one anywhere and need the car for the weekend. hopefully it will hold out like your.

Should do mate, aslong as they seal it up well it should all be fine

 

[spankyro]

it is a very common problem ,it breakes from the vibration of the engine,i welded many of them and they hold good laso the pipe from it to the egr valve breakes the same or between the rings
ant the cost is 50 euro