35d worsening gas mileage - solved- thermostat/fan/EGR cooler - DIY with pics

[scorpioy]

Hi, ZetaTre, could you specify the e-torx size you used for flange bolts.
What's the torch amount you used for different bolts?

Thanks

[ZetaTre]

Originally Posted by scorpioy

Hi, ZetaTre, could you specify the e-torx size you used for flange bolts.
What's the torch amount you used for different bolts?

Thanks

I don't remember what they are. I do have a set of Torx so I try them all out. I didn't really spec torqued them. I just went "gutten tight". Just link other things in life, lubrication is key: the flange bolts seize easily in the cast iron manifold so do a dry run before hand and coat them with anti-seize compound (the same used for spark plugs)

[scorpioy]

When you connecting the hoses back to the themostat and EGR, did you apply some silicone gasket or something to prevent anything leaking? Or just use those existing clamps would be enough? I'm a bit worried about that.

Thanks

[ZetaTre]

Originally Posted by scorpioy

When you connecting the hoses back to the themostat and EGR, did you apply some silicone gasket or something to prevent anything leaking? Or just use those existing clamps would be enough? I'm a bit worried about that.

Thanks

I did because I have a habit of lubricating everything, but the connectors have a o-ring inside and they are generally not prone to leaks. Ensure the hose is properly seated and the metal clip is secured and you should be fine.

This is the lube I use on rubber seals and grommets: NAPA AUTO PARTS

One thing about the cooling system: part #1 in this diagram



Is a rigid plastic tubing. You can flex it enough to connect it to the thermostat but it's a pretty scary thing. Consider releasing the bolt #2 holding it in place for simplicity. I believe I was able to reach to it under the EGR valve.

[scorpioy]

The diagram you posted is not showing up.
Could you just paste a link of it? Thanks

[ZetaTre]

Sorry about that. The diagram is now a clickable link

[scorpioy]

You mentioned 2 flange bolts that are hidden underneath.
In this picture, you pointed one of it with a yellow arrow.
Could you point out where exactly is the other one? I made a Red circle on it, is it there?
Thanks

[sgrice]

scorpioy - Remember that (disregarding radiator hose and electrical sensor connections) the EGR cooler is held in place by a total of five connection points - the circumferential clamp (part #7 in the diagram below), two mounting bolts (locations shown by the two yellow arrows on the picture you reference, and one labeled as part #4 below), and by the two flange bolts (T-45) that connect the accordion end of the EGR cooler to the exhaust manifold. Here is a parts diagram of the EGR in situ:



The diagram only shows one bolt for the top part of the flange (part #6). There is another bolt for the bottom of the flange. You can see that the flange and bolts connect the accordion end of the EGR cooler to the exhaust manifold. The insert diagram above shows the EGR cooler in yellow as it is positioned on the engine. To (hopefully) further clarify things, perhaps I confused you by saying that the red arrows pointed to two mounting bolts? I should have said that the arrows showed the mounting brackets that the mounting bolts go through. I'll edit my original post to make that more clear.

What you circled in red is one of the bolts that attach the EGR valve to the intake manifold. That bolt was never touched for the repair. For the sake of providing information, though, check out the diagram below. The EGR valve is part #1. It is mounted to the intake manifold by four bolts in essentially the four corners of a square. The diagram below shows a bolt (part #3) that fastens a bracket (part #7) and the EGR valve to the intake manifold via the "top driver's side bolt" location. The bolt you circled is not shown in the diagram, but would represent the "top passenger side" location. I may have made that more confusing with a lot of words - it's pretty obvious when you see it in front of you.



Hope that makes sense. If not, post a response and I think we'll eventually get it taken care of.

Regards

[sgrice]

A Good Picture is worth a thousand words! Here is a picture from lpcapital (aka ZetaTre) from his bimmerfest post that got me started down this road (I referenced his post in my original post, but the link is here). Here you can clearly see that the flange at the accordion end of the EGR cooler has holes for the two flange bolts.




Hope that makes it clear.

[scorpioy]

Ok, I think I got it.
You were saying there is another flange bolt at the bottom. So I was think it's somewhere at the bottom of EGR, but it's just the bottom of flange itself. So two bolts on that single flange.
Thanks for such detailed explanation.

Could you provide me the realoem link of the first diagram in your last post?