Coolant internal leak (to the exhaust) on 2.0 tdi

[victory25]

Hello, recently i had a very common problem (like many posts on this forum) with the egr cooler.
But after replacement with an NRF (firm) part, i found that everyday i lose about 100-200 mililiters of coolant and it's going to the exhaust (somehow).
If i drive 100-200 miles a day, at the end of the day i see that coolant level is a little bit lower than in the morning... but next day it's 2-3 times lower...
In the morning the exhaust is white smoking (hard enough to make a difference from smoke and mist) for about 5-10 minutes. And the smoke smells like coolant.

So i don't know, is the problem in NRF egr cooler? Because before changing my car was not losing any coolant ( i check coolant level everyday).
And it is 100% internal leaking.
It started in the first 5 minutes after egr cooler replacement. But i don't know, it's the cooler itself, or boys from the service didn't put back some gasket... I asked them, they said they used old gaskets.

[Elansear]

Bet it’s a gasket, always fit new as they are under compression when fitted so they seal correctly, if you use old ones that doesn’t happen as efficiently.

[Crasher]

The coolant feed to the EGR cooler has no gasketing, hose to pipes. The first step would be a pressure test of the EGR cooling jacket

[victory25]

Hello:)
I've been traveling through "garages" all the week, no 1 can help me... someone is telling me that i have to change new egr cooler, some1 is telling me to change the car and so on... Please, give me an advice.

After replacing the old original audi EGR cooler with a new NRF cooler i still get the error P2002.
P2002 00 - Particulate trap Bank 1 - Efficiency below threshold

Last regeneration: 317 km ago
Soot mass level: 13,64g
Soot mass calculated: -0.23
Oil Ash: 0.09L
Mileage: 136000 km (±80k miles)

The check engine light is still ON with a P200200 error code.
Help please

P.S. Forgot to say 1 thing:
If i delete the error code, the check engine light turns off, but it returns after 48 hours... really, don't know how to explain, but even if i drive 1000km in 48 hours, or not driving at all for 48 hours, the check engine light returns after 48 hours. Within ±48 hours i have no error codes when putting my tester... The error comes only with the Engine light ON.

[victory25]

....

[philipharmes]

It would appear, as you say, that the new EGR cooler is leaking.
The only way forward is to pressure test it as Crasher advises.

I can't see how the cooler was the problem in the first place anyway.
The EGR is shut off during a regen, so can't see how the cooler would affect the DPF regen.

More likely to be the EGR valve itself sticking open preventing the DPF reaching its regen temperature.

Also check there are no sooty leaks anywhere in the pipework between the exhaust manifold / turbo / DPF.

[Crasher]

P2002 is a blocked DPF…

[philipharmes]

P2002 is a blocked DPF…

Assuming that is questioning my reply.
But why is the DPF getting blocked.

If the EGR valve is sticking open ( it should be disabled during a regen ), it stops the DPF getting to a regen temperature.

The same reasoning if there is a leak in the exhaust before the DPF.

[Crasher]

They get blocked anyway, you have no reported EGR system codes.

[victory25]

philipharmes,
i booked a replace of egr cooler and egr valve with OE... can't believe i spent a lot of money for a car with so many problems, or with a problem that is so hard to diagnose... i had a golf 6 on petrol, drove 100k miles (almost) and never been in service (only oil, filter changes and other small things) :D (sorry for offtopic, had to say that)

Why i changed the egr cooler in the first place?
I got a engine light on with a p200200 error. I went to Audi dealer and they took the car for a diagnose, after 1 hour they told me that i have to change the egr cooler. I was stupid and bought a non OE part, now i'm paying for my stupidity (if that is the problem ofc).

[Crasher]

The only stupid person is the one at the dealer who told you a blocked DPF was the result of a not reported faulty EGR valve. Sometimes aftermarket components are not a bad idea, you just have to be selective, this comes from experience and having trade data systems. The way we deal with this code is to remove the DPF and send it away for professional cleaning; once refitted we fit a new GENUINE pressure sensor, calibrate it and then carry out a forged regeneration. So far this process has never let me down and interestingly we have not seen a re-blocking of one we have had cleaned and we still service a lot of the cars we have done this to.

[victory25]

Hi Crasher.
Didn't know Audi dealer can be so wrong :( i just thought everyone is doing their job well, haven't passed through such experience in the past... The audi dealer was the 3rd service i went, because everywhere i was getting just random assumptions, no 1 was like "we have to do that when you are ready", thats why i went to audi(vw).

Now i don't know... since i've changed the aftermarket egr cooler and it's leaking, and today my car started hard smoking with bad smelling (like the EGR valve is constantly closed) and it's losing coolant even faster than ever, i think i have to change the OE egr cooler + valve now and be more carefully in the future... Because before changing egr cooler my car was running well, not losing coolant and not smoking.
If the error will continue after OE cooler + valve replacement, i'll try to do what you said.
But anyway, for the people who will have similar problems in future, this thread will be extremely helpful.

[Crasher]

The bad smell and smoke are from the DPF which is about to collapse.

[victory25]

How can it be possible if:
1. Regenerations are going normal (every 350 miles) and when soot is about 20-25g... and Oil Ash is only 0.09L
2. Car has only 80k miles
I'm just interested if that is possible.
Because all problems with bad smell started 15k miles ago when i got replaced the Timing belt and water pump...

[Crasher]

You have the P2002 code, the readings are guesses made by the ECU

[Itsrainman]

You have the P2002 code, the readings are guesses made by the ECU

Allthough I am in no position to comment on Crashers years of experience and knowledge regarding problems with Diesel cars I have come to the conclusion that mileage has little or no bearing on the life of exhaust parts… The engine seems to last for ever, the exhaust and emissions system is like something that needs constant looking after and generally will have a life significantly shorter than the engine life. Compounded by the fact that DPF’s and associated components are treated as ‘service’ parts by the manufacture and have an end life which was never really communicated to us consumers.

Diesel cars were sold in the UK as low emission and high MPG to which most company car drivers focused their choice on as this delivered the lowest BIK and hence tax out of wages. Up until recently most second hand cars in the UK came from the lease market and hence the company car market. For us as company car owners there tended to be little issue, we kept the car for 3 years and warranty covered the problems. It is only after these three years and the end of the warranty that the subsequent owners pick up the tab.

For those owners that purchase from new, I believe that those that have high ‘mileage’ have the lowest running costs based on a cost per mile driven.

Low mileage almost seems to be the diesels Achilles heal. It’s not even low mileage pursay but the number of journeys driven at low mileage. A car with 12000 miles over three years driven for 4 1000 mile journeys a year each year probably fairs better than a car that has lots of 20 mile journeys over its life.

As Crasher has stated DPR cleaning is required and is almost becoming a requirement of age. Typical cost £1000.00, 50000 miles = 2 per mile, 100000 miles 1 per per mile. Add in the EGR value, cooler and associated parts and costs soon mount up..

Is it cheaper to get a petrol car, personal choice dictates that but it’s something I am seriously considering next time around.

The only problem is that for both diesel and petrol cars one will always struggle to achieve the recommended MPG and hence its very difficult to estimate any kind of lifetime cost!

[Crasher]

As I do such a low annual mileage, thankfully running costs (particularly fuel) is not something I consider, I would not like to be in the position of having to do 10K+ a year especially with a company car as I hate small Diesel engines, they are a crime against humanity.

[johnydriver]

Hello all.
Changed the EGR cooler with Original one + EGR valve.
Now the coolant is not leaking (or it hasn't for first 2 days, what will be next i don't know), and no smoke from the exhaust for the first 2 days (again, i don't know what will be next, but it's been 2 days since changed).
The old EGR valve was total trash, full of soot and blocked. Aftermarket EGR cooler (which was new and changed recently) was also broken.
P.S. please, do not use aftermarket parts for this cars, it's a big chance to pay twice, like me