EGR Cooler REplacement

[T Rex]

About 600kms ago my Touareg wanted a coolant top-up. Took almost 3 litres. 600km later it needed another 2 litres. No sign of external leaks but internet search revealed it could be the EGR cooler leaking into the exhaust system. Took to dealer today and suspicions confirmed - unfortunately engine out job. 6 months out of warranty but hopefully VW will come to the party. Anyone else had similar experience? Geoff

[njg02]

I almost bought a V6Tdi but it had low coolant and check engine alarm. So far I'm happy with my R5.

[T Rex]

Hi njg02. Glad you are happy with your R5. I am overwhelmingly happy with my Treg and the service from my dealer has been fine. It is undoubtedly the best proper (dual range) 4WD I have owned over the last 30 years. I am hoping VW has the integrity to do the right thing with this fault which obviously should not have occured. Cheers. Geoff

[GoLfMan]

maybe research into an EGR delete for the Touareg? You'll never have a problem again!

[T Rex]

maybe research into an EGR delete for the Touareg? You'll never have a problem again!

Now that IS lateral thinking! Mind you there is a very long list of complicated technology I would love to delete from modern cars.

[Ratstylz]

Wow engine out ???. I have changed several of these and didnt take the engine out...... They were all V6TDI

[T Rex]

Wow engine out ???. I have changed several of these and didnt take the engine out...... They were all V6TDI

Hi. That's what I thought looking at the workshop manual and indeed VW has confirmed that it is not an engine out job. Thank goodness.

[Ratstylz]

Hi, Check this out, might help with the cost..

Technical product information Transaction No.: 2018615/9
Engine: Coolant warning light on, no leak on outside, exhaust recirculation cooler leaks Release date: 18-Aug-2010

Customer statement / workshop findings

Vehicle consumes coolant. No coolant loss to the outside.

Technical background

The coolant loss can be caused by a leaking exhaust gas recirculation cooler. As a result, the leaking coolant is burnt.

Production change

Optimised cooler for exhaust gas recirculation from manufacturing date: 02.07.2008

A: manufacturing date




Engine number from:

CARA: no change Phaeton

CEXA: 002053 (04.07.200 Phaeton

CASA: 040744 (04.07.200 Touareg



Chassis numbers from :

Touareg: WVGZZZ7LZ9D
Measure

Free or remove the EGR cooler. Coolant marks within of the EGR module can be seen either with the naked eye or with an endoscope. In most cases, there are also incrustations on the exhaust gas temperature sensor.

If this is so, replace the EGR cooler.


Check the complete exhaust recirculation system for coking and clean the affected areas.

Warranty accounting instructions

Service number/damage code/manufacturer: 2643 / 0050


Accounting with APOS



Repair operation number
Designation
Time units (TU)

Phaeton 3D*

Main operation
26 43 19 35
Remove and install EGR cooler
570

Associated operation
26 43 01 99
Check EGR cooler
20

Associated operation
26 43 29 99
Clean EGR system
*

The repair operations include all the work of this TPI.





Repair operation number
Designation
Time units (TU)

Touareg 7L*

MKB: BUN

Main operation
26 43 19 34
Remove and install EGR cooler
420

Associated operation
26 43 01 99
Check EGR cooler
20

Associated operation
26 43 29 99
Clean EGR system
*

The repair operations include all the work of this TPI.





Repair operation number
Designation
Time units (TU)

Touareg 7L*

MKB: CAS*

Main operation
26 43 19 37
Remove and install EGR cooler
680

Associated operation
26 43 01 99
Check EGR cooler
20

Associated operation
26 43 29 99
Clean EGR system
*

The repair operations include all the work of this TPI.



Accounting with APOS/2:

Model
Illustration
Position
Number
Designation
Activity
Time units

3D*
131-55
1
131511
Remove and install EGR cooler
19
*

3D*
131-55
1
131511
Check EGR cooler
02
20

3D*
131-55
1
131511
Clean EGR system
30
*

The repair operations include all the work of this TPI.



Touareg 7L*

MKB: BUN

Model
Illustration
Position
Number
Designation
Activity
Time units

7L*
131-60
1
131512
Remove and install EGR cooler
19
*

7L*
131-60
1
131512
Check EGR cooler
02
20

7L*
131-60
1
131512
Clean EGR system
30
*

The repair operations include all the work of this TPI.



Touareg 7L*

MKB: CAS*

Model
Illustration
Position
Number
Designation
Activity
Time units

7L*
131-65
1
131511
Remove and install EGR cooler
19
*

7L*
131-65
1
131511
Check EGR cooler
02
20

7L*
131-65
1
131511
Clean EGR system
30
*

The repair operations include all the work of this TPI.


The labour times are correct at the time of publication. The time units (TU) may differ slightly, if the repair catalogue has been updated. The information in the repair operations catalogue applies, except for the open time items (... 99).

The necessary time for using the diagnostic tester are not included in the above times; they are kept separate.

Use the above times only for this TPI.

[T Rex]

Thanks for that. If anyone has a good email address for warranty support at VW Australia I would appreciate it. Sent an email to the only address I could find on their website (volkswagenassist@) on Thursday morning - not even an acknowledgement yet.

[T Rex]

Update. The problem has been fixed. EGR cooler replaced by dealer. VW paid for part and 50% of labour as goodwill so at least that is a positive story about VW. My contribution approx $500 including various seals that also needed to be replaced. Can't complain. Better to fail now and be fixed rather than halfway across the Simpson Desert!