Hi again, some of you might've seen a recent post I made asking for ideas about an air leak under the bonnet of my 1.9 tdi PD Octavia.

 

I've found that the intake pipe between the EGR valve and the intercooler has a loose connection at the EGR end so I'm hoping that will be where the leak is. My problem now is that the connection seems to be a different type to most of the other hoses clamped with the circular clip things. The pipe on my engine seems to have some kind of metal fitting attached to the pipe itself which slots into the EGR.

 

I've found a couple of photos online which hopefully show what I'm talking about. The first one just shows the location of the pipe (in the white circle), and the second one shows a pipe I saw on ebay which seems to have the same kind of metal connector thing as mine. If anyone can fill me in on how this fitting works etc I'd be very grateful! Cheers.

second picture is the hose wich connects into the pancake near the wheel and is for the petrol engines

 

you need this:

 

Edited 27 April, 201511 yr by IulianE

Oh right thanks for that.

 

Can you give me any more detail about how the pipe actually fits to the EGR?

 

On mine it doesn't look like the other pipes that are clamped with the circular clips. It has a metal piece on the end like the 2nd picture which seems to slot inside the EGR rather than fitting over the top...

This is the sort of connector that I'm talking about. Just need to find out how it actually fits to the EGR.

what engine code do you have?is the hose with metal end or not?

Not sure of the engine code off hand but I have a feeling it's ASZ. That seems to ring a bell.

 

Yes the hose on mine has a metal end. I just can't quite see how it secures to the EGR...

Ok,now I understand....I was wrong,the first pictures are right ,that is the hose for you with metal end.It secures on EGR by a C clamp

 

 

this is the OE code for that hose 1j0145838af and 1j0145769c is the C clip

Edited 27 April, 201511 yr by IulianE

Oh right ok thanks. Glad to hear I'm finally getting somewhere haha. Kind of wish it was one of the simpler connections so I could just clamp it on properly with a big jubilee clip!

Just went under the bonnet to have a look and it does indeed use that kind of connector with the C-clamp you mentioned.

 

I have to say it doesn't seem like the best design in the world. I can't really imagine it ever being very air-tight. The clamp doesn't even hold the pipe in place, it just locks it from popping out, but doesn't stop the pipe moving about in the EGR. The fact that I removed the clip without tools didn't fill me with confidence either! Seems to me that a good old fashioned jubilee clip or something clamped tight around the hose would be much more effective...

I was going to say it looks like it could be one of those. Got one of those where the rubber intake pipe goes into a metal lower section then onto turbo on the petrol. You're right I'd prefer a more traditional clip. I think it's the O ring that creates the seal but even so. Have to unclip mine as I have a replacement TIP to fit, think getting that clip back on may be easier if I take out both sections, bit of a pain. Anyway a bit off topic sorry about that, glad to see you're getting somewhere.

No worries, good luck with yours. Sounds like a bit of a hassle...

 

That's a good point maybe I'll replace the O ring first before anything else an see what happens. I don't suppose anyone knows a good site to get part numbers etc from?

I went for the radical solution,glued it with Bison Metal,is practically like welded

The pipe you're looking at with the metal collar on the end is a standard VAG diesel boost-pipe connection, my old Passat had them.

 

To disconnect, carefully lift the C-clip by inserting a hook or screwdriver under the little raised loop, then pulling carefully but quite firmly. It won't come all the way off, but once lifted the pipe should just pop out.

 

Once removed, clean around the female side (the EGR intake) and the male side (pipe) with a bit of rag to remove any black sludge.

 

On the pipe end, there should be a thin rubber seal; original ones are black and have a tendency to leak over time, they ideally need to be changed for the green ones from TPS as they're not expensive, very slightly fatter and make a much better seal.

 

After you're happy with your freshly cleaned pipe/seal etc, the clip on the EGR connection needs to be returned to its original position, a squirt of oil onto the pipe-end to prevent the seal from gripping on its way, then push the pipe firmly and positively back where it belongs (you should hear a distinct "Click" as it goes home).

 

Hope this helps!

I think is correct to say is the low end standard for VAG cars 

That's great thanks very much for that. Always good to have a nice clear set of instructions!

 

So is it normal for there to be a bit of play in the connection? Or will that hopefully go away when I replace the seal with one of the fatter ones? (I really hope so because it just seems a bit wrong for an 'airtight' connection to be rattling about!)

 

On the pipe end, there should be a thin rubber seal; original ones are black and have a tendency to leak over time, they ideally need to be changed for the green ones from TPS as they're not expensive, very slightly fatter and make a much better seal.

 

I went to TPS yesterday and asked about the fatter green O-rings but the guy didn't seem to know what I was on about unfortunately. In any case he reckoned a new seal would only be a temporary fix without replacing the pipe itself, because of the worn down lug bits, so I was persuaded to go the whole hog.

 

Just finished fitting the new pipe and was disappointed to see there's still quite a lot of play in the connection. And when I took it for a quick test drive I could still hear the air leak, so unless the O-ring will swell up and gradually seal the connection with a bit of driving, it looks like I've got nowhere!

That's a bit pants. Did you say you'd had a smoke/pressure test done?

No nothing done yet. I just saw how loose that connection was and assumed I'd found the leak. I haven't really got time to fiddle any more so think it might be off to the garage with it. Bloody annoying!

I'd have thought the same as yourself, pressure test will reveal the culprit.

Just been looking on ebay at pressure testing kits an it's actually very tempting to have a go myself but at the same time I just want to get it sorted really. Hopefully the garage can get it sorted nice and quick (and reasonably cheaply!). We shall see...

 

 

you need this:

 

 

Sorry mate just out of interest, where did you find that picture? Is it from a parts catalogue? I'd love to get hold of one of them at some point!

Is Etka

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Cheers just found it. Useful little resource!