EGR Cooler Leak?

[Vx-Man-G]

Hi folks,

After some help please.
We're losing slight coolant on our W204 CDI 2.1 / 2010.
The only place obvious is this area in the below image, its literally where the aluminium pipe joins the part, I believe the part is the EGR cooler??? Is this a common place to leak? Only reason we think its this is because there is like a blob of what looks like dried out coolant.

Picture in pinched off the Interweb.

If this is the offending component, how difficult is this to change?

Also, I have attached a further picture of a part off ebay, is this the one?

Thanks.

 

[M80]

It looks like the one, but confirm by part number when it's off.
It's held by 6 torx bolts, that should be E6, but 2 of mine were different as E8 but still m6 thread.
2 of those bolts hold the cooant U bend in place above.
2 bolts below are reachable by use of long extensions, but 1st

Loosen the fuel pressure sensor at the front and bottom of the fuel filter manifold 1x E10,
Remove the dip stick tube so it can be rotated some, I think 3x E10 (one being on top of the cooler.
Remove top bracket to cooler.
Remove E10 bolt from underside bracket.

If you're lucky that's the issue but the plumbing on these is extensive., in fact your arrow points to one hose to the fuel filter heater.

 

[Vx-Man-G]

It looks like the one, but confirm by part number when it's off.
It's held by 6 torx bolts, that should be E6, but 2 of mine were different as E8 but still m6 thread.
2 of those bolts hold the cooant U bend in place above.
2 bolts below are reachable by use of long extensions, but 1st

Loosen the fuel pressure sensor at the front and bottom of the fuel filter manifold 1x E10,
Remove the dip stick tube so it can be rotated some, I think 3x E10 (one being on top of the cooler.
Remove top bracket to cooler.
Remove E10 bolt from underside bracket.

If you're lucky that's the issue but the plumbing on these is extensive., in fact your arrow points to one hose to the fuel filter heater.

I think I will ask my dad to take an actual picture of where the build up is so we can get a proper view of it.

Is it a hard job and is it DIY ?

 

[M80]

Seems like your less sure it's the EGR cooler.

The EGR cooler is known to perish inside mixing coolant with exhaust, from that there might be evidence of white, sweet smelling exhaust smoke.

The fuel filter has a heater that is warmed by coolant, they are known to leak onto the inlet manifold below, then it might travel anywhere before going down.

Tbh I would remove belly pans and when parked on a dry surface try to get an idea where the leak originates.
Removing the EGR cooler is doable but v awkward. But if the leak i external it may be it needs nipping up, but not too tight the threads are only aluminium.
It may be as simple as a weeping / split hose.

 

[Vx-Man-G]

Seems like your less sure it's the EGR cooler.

The EGR cooler is known to perish inside mixing coolant with exhaust, from that there might be evidence of white, sweet smelling exhaust smoke.

The fuel filter has a heater that is warmed by coolant, they are known to leak onto the inlet manifold below, then it might travel anywhere before going down.

Tbh I would remove belly pans and when parked on a dry surface try to get an idea where the leak originates.
Removing the EGR cooler is doable but v awkward. But if the leak i external it may be it needs nipping up, but not too tight the threads are only aluminium.
It may be as simple as a weeping / split hose.

Yeh, I see. The car has had an Oil Cooler replaced last year, but this build up, of what looks like crud, seems to be very isolated to that one junction.

 

[Dean Fletcher]

Looks like a om651 fuel filter housing problem very common had mine done not so long ago.

 

[Vx-Man-G]

Looks like a om651 fuel filter housing problem very common had mine done not so long ago.

What is that?

 

[Vx-Man-G]

Sorry, where?

 

[Dean Fletcher]

Sorry, where?

It is located directly under the fuel filter.

 

[Dean Fletcher]

 

[Dean Fletcher]

You should see fluid here

 

[Vx-Man-G]

Thank you, I will inspect at the weekend.

 

[Gazwould]

It's had a redesign to help with it's shortcomings .

 

[Dean Fletcher]

It's had a redesign to help with it's shortcomings .

View attachment 70750


View attachment 70751

My car never had a hole for the upgraded 3rd bolt. Still fitted it anyway

 

[Vx-Man-G]

Here are some pictures..

It's actually not from the pipe, but looks like it's settling on the pipe.

Any help and guidance would be appreciated.

Thanks in advance.

 

[Dean Fletcher]

Here are some pictures..

It's actually not from the pipe, but looks like it's settling on the pipe.

Any help and guidance would be appreciated.

Thanks in advance.

Have to tried cleaning it then letting the engine run for a while? The car will need to get up to temp. Looks close to the egr cooler

 

[M80]

That elbow pipe is the exhaust feed from the EGR toward the back of the engine.
That gasket, if compromised, would only allow exhaust gasses to pass.
The cooler has water passing through it,the gasket between that and the EGR is the same as it only holds exhaust gasses within. But if the cooler was split then maybe, but I don't see that.


The fuel filter warmer sits above. It bolts to the head and coolant passes through it, is is known to leak. It's plastic so could very well be that.
I don't see removal as easy, but doable.

1431a shows the elbow from the rear, engine out.
1433a is the fuel warmer off and above where it sits, the elbow is removed or you would see it into the aperture below.

 

[Vx-Man-G]

That elbow pipe is the exhaust feed from the EGR toward the back of the engine.
That gasket, if compromised, would only allow exhaust gasses to pass.
The cooler has water passing through it,the gasket between that and the EGR is the same as it only holds exhaust gasses within. But if the cooler was split then maybe, but I don't see that.


The fuel filter warmer sits above. It bolts to the head and coolant passes through it, is is known to leak. It's plastic so could very well be that.
I don't see removal as easy, but doable.

1431a shows the elbow from the rear, engine out.
1433a is the fuel warmer off and above where it sits, the elbow is removed or you would see it into the aperture below.

Thanks.
Everything you have just said makes it sound like a pain in the a55 job.

I am still a little confused though.

 

[Dean Fletcher]

Thanks.
Everything you have just said makes it sound like a pain in the a55 job.

I am still a little confused though.

Here's the video I used when doing mine

 

[Vx-Man-G]

This looks an absolute pig of a job. But ours doesnt seem to have any coolant anywhere else! Its just that blob I showed in the pictures!