audi a2 1.6 fsi (bad) remove / refit instructions needed for EGR PIPE replacement diy

m70wse

m70wse

Member
with my photos & muggles instructions have a go yourself.

parts list

p u036 131 521 bn n/stk pipe qty 1 unit price £78.00
p u036 131 550 c h.1.6.b gasket qty 1 £1.00
p un 903 659 07 n/stk screw qty 4 £0.44
p u036 131 547 c h.1.7.a gasket qty 1 £1.92
p u036 906 149 e n/stk seal qty 1 £1.61
p un 100 802 04 n/stk bolt qty 3 £0.52
p un 909 865 01 n/stk clip qty 1 £0.96
 
Last edited:
Mine went after 7 years / 65 000 miles.
I had this replacement done by local (genuine, non-independent) VW garage. Parts (pipe & 2 gaskets) were £70, labour was £82.50, with VAT on top (Sept. 2009 prices).
Considered doing it myself but I think the fuel pump (on the end of one camshaft) should be removed, and it started to look fiddly. I think those with the knowledge can find short-cuts!
Not sure whether replacement pipe is improved - its been OK since.
Hope this helps!
 
don't be put off by the High pressure fuel pump removal.
This can be done by a competent diy mechanic

You'll need a good long spline bit to undo the bolts on the EGR connecting pipe - M8 I think. The temperature sender is in the way at the exhaust manifold end if you have a stubby bit.

Don't forget to order a new O-ring for the Fuel Pump for reinstalling

First:
Remove fuse for fuel pump first then let engine run until it stalls- repeat to ensure that pressure reduced in fuel system.

Then loosen pipe connecting fuel pump to high pressure fuel rail at both ends (have a rag to catch small amount of petrol)- with this free the fuel pump can be removed.

Now you can easily remove the 2 bolts each end holding the connecting pipe in place.

Next clean the EGR valve and Exhaust manifold where the pipe connects.

Reffitting is reverse of above.

Should be do-able within an hour.

A satisfying little job really - pics would help to explain above but its wet / dark and I can't capture screen images from ElsaWin right now.

Pete
 
This is very helpful, thank you. A cursory check shows that the pipe price has come right down but I am ready to be disappointed. Having disturbed the pipe to get the manifolds off I am not getting a lovely smell of uncatalyzed vPower fumes into the cabin when stationary. Well, that's what I think it is - can't be sure if the O rings on the fuel rail are leaking until I've dealt with this smell!


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Well, now changed and working well, no more smell in the cabin. Audi have changed the bolts to Torx. The lower one on the exhaust manifold was a sod to do up, would be very hard to turn clockwise but span freely anti-clockwise. It didn't feel like a cross thread but there is so little space to work down there I haven't managed to get it out again to have a look.


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m70wse said:
with my photos & muggles instructions have a go yourself.

parts list

p u036 131 521 bn n/stk pipe qty 1 unit price £78.00
p u036 131 550 c h.1.6.b gasket qty 1 £1.00
p un 903 659 07 n/stk screw qty 4 £0.44
p u036 131 547 c h.1.7.a gasket qty 1 £1.92
p u036 906 149 e n/stk seal qty 1 £1.61
p un 100 802 04 n/stk bolt qty 3 £0.52
p un 909 865 01 n/stk clip qty 1 £0.96
Click to expand...
Thanks for posting this! just about to give my FSI EGR pipe replacement a go.
 
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