VW TDI forum, Audi, Porsche, and Chevy Cruze Diesel forum banner

1 - 14 of 14 Posts

·
Registered
Joined
·
2 Posts
Discussion Starter #1
2006 Jetta TDI-
I'm in the process of replacing the EGR cooler and can't seem to get the thing out. All has gone well so far, but thought I'd ask if that steel oil line behind it needs to come off.
Please advise. Thanks!
 

·
Premium Member
Joined
·
20 Posts
There is a bolt or two that is almost hidden. I had trouble on my 04 with the intake manifold off the car and cooler still attached. I hear the 06 engines are even worse (complicated) on the EGR system.
 

·
Registered
Joined
·
2 Posts
Discussion Starter #4
I figured it out myself- the turbo oil line definitely has to come off to allow the EGR cooler to drop down, even after some twisting and maneuvering.
This is not a bad job, but not one for the novice mechanic. (I have not turned wrenches in a long time, but my good basics and instinct came into play) My advice is to take your time and use quality tools, so you do not round anything off. I'm also coating some of the hard to get bolts with anti-seize in case this thing needs replaced again.
One thing for sure- the EGR cooler removal steps in this previous post below do not even come close for the 2006 Jetta, as nothing has to be done from the top.

http://www.myturbodiesel.com/1000q/a5/clean-intake-manifold-PD.htm

Now that I'm a one-time "expert", feel free to contact (me) if I can be of assistance.
 

·
Registered
Joined
·
5 Posts
when you removed your egr cooler did you remove your exhaust to get it out? or just unclamped it from the turbo? Im in the process now. 1 allen bolt stripped so im trying to figure out how to cut it off in such a little space!! another thing, is ther any precaution bout taking the turbo oil line off?
 

·
Registered
Joined
·
5 Posts
Thanks for the reply Chitty. It actually all went well! the loud hissing is gone and no leaks anymore! now I wish I had taken video n pics of the job, to help out the forum. This forum has done so much for me n my Jetta, I have to start giving back!
 

·
Premium Member
Joined
·
23,902 Posts
Thanks for the reply Chitty. It actually all went well! the loud hissing is gone and no leaks anymore! now I wish I had taken video n pics of the job, to help out the forum. This forum has done so much for me n my Jetta, I have to start giving back!
No problem, there is a donation button at the bottom :D I think I'll move it to the top though.
 

·
Registered
Joined
·
5 Posts
I had to replace the EGR cooler, because the vacuum valve on the cooler was making a loud hissing sound n loosing vacuum. No option but to replace whole unit, unless you make a new valve yourself n not no how long it will last.
 

·
Registered
Joined
·
3 Posts
I have a similar problem except 2 stripped bolts, the bottom two bolts that mount the egr cooler (BEW engine) to the intake manifold are stripped so the 6mm hex won’t work. On top of that I have a 10mm and 11mm stripped bolt extracting sockets that wont work either (the 11mm is to loose and the 10mm wont seat enough to get any tension on it). Any ideas on how to remove them without messing anything else up? Cutting the bolt heads was mentioned but I have no clue what tool one would use to cut the bolt heads in such a confined and awkward place. Is it possible to cut the mounting bracket portion off the egr cooler and deal with the bolts after removing the intake manifold from the engine head (this was my initial thought but figured I would try and get a second opinion, the cooler will be scrapped anyways)? Any thoughts or suggests are always appreciated. Thanks!
 

·
Registered
Joined
·
3 Posts
Ended up being able to remove the intake manifold with the EGR cooler still attached.Once everything was out of the engine bay I was able to loosen the stripped bolts.
 

·
Registered
Joined
·
24 Posts
I figured it out myself- the turbo oil line definitely has to come off to allow the EGR cooler to drop down, even after some twisting and maneuvering.
This is not a bad job, but not one for the novice mechanic. (I have not turned wrenches in a long time, but my good basics and instinct came into play) My advice is to take your time and use quality tools, so you do not round anything off. I'm also coating some of the hard to get bolts with anti-seize in case this thing needs replaced again.
One thing for sure- the EGR cooler removal steps in this previous post below do not even come close for the 2006 Jetta, as nothing has to be done from the top.

http://www.myturbodiesel.com/1000q/a5/clean-intake-manifold-PD.htm

Now that I'm a one-time "expert", feel free to contact (me) if I can be of assistance.
 

·
Registered
Joined
·
24 Posts
did you remove off a 2006 tdi? Because i want to learn how to do that myself, if you can help i would appreciate it
 
1 - 14 of 14 Posts
Top