Audi A6 ‘2007 3.0 TDI. Complete removal of the EGR system and intake manifold flaps.
The car AUDI A6 2007 ASB (TDI) arrived with a wholesale range of problems, from a trivial unstable XX to a “turbine underflood”, expressed in unsatisfactory dynamics (to say the least).
Immediately struck by the detached thrust of the intake manifold flap drive (B1), a malfunction characteristic of this type of engine. Errors in slurred control of the turbine geometry gave an answer to the questions on under blowing, but it was necessary to find out the reasons. Since we already had some experience and developments in this direction, it was decided to first check the EGR system.
Why EGR? Many owners of Vagov cars with similar diesel engines (Q7, A6, VW TOUAREG 2.7 3TDI, etc.) have already experienced what surprises this system can throw. Here we want to tell about them.
To begin with, we tear out everything that is “connected” with EGR. The word “Full” was used in the title for nothing, the fact is that we decided to disable this system both programmatically and physically remove all components.
Remove the vacuum tubes and solenoid valves of the EGR actuator.
To facilitate access to the EGR vacuum actuator, you will have to remove the intake manifold, however, given the problems with adjusting the flaps, you would still have to do this, but more on that later. Remove the fuel pipes.
And the intake manifold
We twist the vacuum valve drive together with the tube.
As we see, there are NO flaps. And this is an alarm. Above, I mentioned some experience in working with such systems, and precisely because it is not the first time we encounter such malfunctions, we first decided to look into EGR. The fact is that physical damage to the damper is a fairly common occurrence in these engines. In its diameter, it does not creep into the channels, but this rarely happens, and in most cases it breaks into two halves which rush towards the turbine with all the consequences. And “leaky” is, as a rule, a breakdown of geometry.
Considering the venerable (317 tyk.) Car mileage, the owner made the (correct) decision to replace the turbine.
We change, after muffling the EGR channels with special plugs made to order. Given the high temperatures at the outlet, the plugs are made of a thick (5 mm) plate. In general, in “nature” there are factory Vagov plugs (038 131 925 A, 038131925), but the part is rare and, as a rule, it is not available at the right time.
However, the wreckage has not yet been found and there will be no rest for us until we find them. We decided to open the geometry of the turbine and all suspicions were immediately justified.
Debris stuck in geometry, severely damaging flaps.
However, these are not all the surprises of the EGR system. She has another, quite serious sore that many owners of diesel AUDI have encountered – a leak of coolant (coolant) through the radiator of this system. The disease is quite insidious, as a rule, expressed with an inexplicable coolant leak in the engine and with its very deplorable results. I will not describe them, a lot has been said about this. I can only say that having climbed into such a jungle, we decided to remove the EGR cooling radiator to the heap. Although there were no signs of leakage in it, it is said – done.
By hook or by crook we root out this knot. Now we need to deal with coolant inlets.
We sort of figured out the EGR, now it’s the turn of the intake manifold flaps. We also own the technology for their complete removal. Physically remove the flaps themselves
And also their electric drives
Put everything in place,
Do not forget to muffle the EGR channel and the intake manifold
That’s actually how it was:
As they say, cut off all the “excess”.
And we have already accumulated a lot of this good:
Who needs contact.
Then Melkon and Ratkov come into action – our diagnosticians Vlad Melkonyan and programmer Petr Ratkov:
Under this car, the firmware is written and poured and the ASB 3D TDI engine turns into YaMZ 236 (a joke).
But seriously, Vlad – he has long been recognized by our customers as one of the best diagnosticians working on Vagov cars, fanatically devoted to AUDI, highly professionally owning any diagnostic equipment for these brands of cars. His contacts, suddenly someone will need: 8 916 158 86 86
Petr Ratkov is a graduate of MADI, a highly skilled specialist with many years of experience working with diesel engines. He devoted several years (and his own cars) to the study and improvement of control programs for ECUs of Vagovsky diesel engines. He has many of his own developments in this direction. Here are his contacts: 8 925 518 68 30
Well, your humble servant is Arsen Ganiev (contact for communication: 8 926 867 65 27), keys, screwdrivers, soldering irons, a little computer and, of course, the hands of our car service.
© Legion Avtodata
Odintsovo (Moscow region), 5, Bakovskaya St., Bakovsky ATC.
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