Leaking EGR Valve?

[ramirezt]

Hello All,

I have a 2005.5 Jetta TDI (BRM) DSG running B100 for about 4 months now with not issues. I changed the fuel filter about 2 tanks of B100. I have been trying to figure out were I hear a hissing sound when the car is under load. The car starts/idles/runs great. This leaking air has affected my MPG's and would like to fix this soon. The only weird thing in 2nd gear while in "D"or manual shifting at about 2000 rpm's the car has a slight surge in power. Nothing drastic, I barely feel it, I have a vagcom cable and use engine basic setting 011 to get the car to rev while I am under it. This is the log:


Address 01: Engine (03G 906 016 AC)

17:26:57 Group 011: Charge Pressure Control
1176 /min Engine Speed (G28)
3.3 mg/str Charge Pressure Control Status
928.2 mbar Boost Pressure (actual)
80.1 % Charge Pressure Control Duty Cycle
Thursday,04,August,2011,17:28:08:46937
VCDS Version: Beta 11.3.0 (x64)
Data version: 20110601


Address 01: Engine (03G 906 016 AC)

17:28:06 Group 011: Charge Pressure Control
1407 /min Engine Speed (G28)
ON Charge Pressure Control Status
1091.4 mbar Boost Pressure (actual)
90.3 % Charge Pressure Control Duty Cycle

The first thing I notice is that the difference between the actual boost pressure is 163.2 I read somewhere that it should only vary between 80-100.

http://youtu.be/Nmac24alpME

This the video from where I can feel the air leaking.

If I pinch one of the bottom vacuum hoses from the n75 valve I can make the noise to go away, I don’t understand the relationship though.


My questions are:

1. In the video, is that the EGR Valve? If not what is it called

2. If I miss diagnosed it, what is the FIX

Any help will be appreciated

[50mpg]

Is that the side of the engine? If you put soapy water around the leak you're sure it's leaking there? Whatever it is, I'm sure it's not supposed to leak air.

[ramirezt]

from underneath the car, between the firewall and the engine

https://mail.google.com/mail/?ui=2&i...961548800-1&zw this is a picture of the area. You can see the area covered in soot, about half way down the silver pipe running down the picture

[ramirezt]

yes I tried the soapy water when the car is cold, and when I turn the car on and enable the basic control setting on 011 engine. the air is flowing and water goes everywhere

[chittychittybangbang]

That is the EGR bypass flap. It uses vac to move a flap. It sounds like something is wrong since you pinch the vac line and it stops the noise. The EGR valve is the black electric motor on the intake manifold.

A bad valve is not an uncommon problm, check to make sure there aren't any outstanding recalls on your car or see what the dealer can do (for free), otherwise I'd just replace it, not supposed to be leaking there.

[ramirezt]

Chitty,

Thank you for the clarification on the name of the part, I was clueless. I will look on how to replace just that flap. thanx again

[ramirezt]

Just wanted to post this picture, the air is coming out from the red arrows. EGR bypass flap?

[damlot]

My 2006 jetta TDI also leaks from that bypass flap(valve). is there a gasket in there? Can just the valve be replaced? My dealer says you have to buy the whole cooling assembly for $401.00 not just the valve.

[ramirezt]

damlot, I had to by a new EGR cooler. It was leaking from the shaft of the the flapper valve on the egr cooler. It took my about 5 hours to replace it. It wasnt hard, just tidious. I have read that you can have a machinest make you a new bushing and replace it.

http://forums.tdiclub.com/showpost.p...63&postcount=9 check that out if you want to have a bushing made. hope this helps

[indy_tdi]

ramirezt,
Was it necessary to remove the half shaft or any other drive-line components? Replacing mine this month - probably. Thanks in advance.
Jeff