Hissing Egr Cooler

[t-aslam]

Hi guys,

Over the weekend I removed the intake manifold from my 05 galaxy for a clean. After re installation inm can hear a really loud hiss which is louder under acceleration. From what I can see and observe it's the egr cooler. Hissing pressure changes as I move the cooler around a little (unbolted). I was thinking about blanking the cooler off at some point before the leak. If I blank off before the cooler this shouldn't be a problem should it? Thanks for your help.

[insanitybeard]

I would say it shouldn't be a problem as long as by bypassing the coolant flow through the cooler it doesn't prevent coolant flow to anything else on that coolant circuit. It may also affect emissions slightly as the exhaust gases passing back into the intake will theoretically be hotter.

[t-aslam]

What I meant was blanking off the exhaust gas from entering the cooler, ie effectively decommissioning the egr valve.

[t-aslam]

Problem is if I blank off under the egr valve I've still got a leak.

[insanitybeard]

What's leaking? Is it coolant into the cooler or Exhaust gas from the cooler? Not just one of the gaskets not sealing properly?

[t-aslam]

Exhaust gas leak from the cooler. I had to push the cooler back when I disconnected it from the egr as I couldn't access the intake manifold bolts otherwise. I think this may have damaged it. Which is why I want to block it off from the exhaust side. I'll leave it in situ for coolant to flow through as normal. Edited May 29, 2014 by t-aslam

[insanitybeard]

Easiest way in that case may well be to replace the gasket on the turbo side of the cooler with a solid disc made from a sheet of thin metal (possibly not aluminium though as it might not be able to withstand the temperature) - just drill a couple holes for the bolts- to stop exhaust gases entering the cooler.

[t-aslam]

So that would be a blanking plate from eBay then. I ordered one yesterday for

[insanitybeard]

Just bear in mind that 'officially', effectively disabling the EGR system on a vehicle fitted with it from new is an offence, in practice, unless it raises the emissions substantially so that it doesn't pass the MOT test, it shouldn't cause any issue. 

[t-aslam]

Yeh I can't actually physically feel any leak around the egr cooler. This hissing is so loud and even present at idle. When I push the car it gets faster. Going to inspect the egr itself one more time. Also going to check the intake manifold bolts. Edited May 30, 2014 by t-aslam

[t-aslam]

Problem found. It is in fact the egr cooler. The flexible part of the pipe that comes of the exhaust was pounding out hot air thanks to a tear caused by me bending it back and forth to access the intake bolts.

[insanitybeard]

If it's just the pipe from the turbo/ exhaust into the cooler itself it is available as a separate part (assuming you can be bothered to change it instead of just blanking the EGR off) - item 6 on this parts diagram- don't trust the part number it gives if you do go to order it though!

Edited May 30, 2014 by insanitybeard

[t-aslam]

I'm going to blank it for now. I'll see if my local TPS will let me have that pipe section at a good price. Thanks for your help insanity beard. Appreciate it.

[t-aslam]

I've blanked off the egr from the exhaust side and directly under the egr valve itself whilst leaving the cooler in situ to allow coolant flow. Do I also need to plug the vacuum hose that attaches to the flying saucer?

[insanitybeard]

You can do to stop the valve from operating but if the flow of exhaust gas is blocked it shouldn't really matter.