Replacing 3.0 TDI EGR Cooler Bypass Valve to Solve Porsche Cayenne Diesel Engine Valley Coolant Leak
In this video I follow up on the engine valley coolant leak my 2013 Porsche Cayenne Diesel 958 is suffering from and solve it by replacing the EGR bypass valve 059121737AM .
This engine is shared with other VAG vehicles with the 3L V6 diesel such as Audi Q7, Q5, A8, and VW Touareg 3.0 TDI, so this how to guide to fixing your coolant leak applies.
Here's the parts list to do this job properly:
Updated EGR Bypass Valve: https://ebay.us/vKCbCF (change this!)
EGR Cooler Intermediate Flange: https://ebay.us/NKtZX7
Oil Cooler Gasket Upper: https://ebay.us/q08wxp
Oil Cooler Gasket Lower: https://ebay.us/B94hkI
Intake Manifold Gasket Set: https://ebay.us/E5elGN
Intake Throttle Pipe Gasket: https://ebay.us/2hQafQ
Throttle Body Seal: https://ebay.us/EVzpki
Intake Manifold Gasket: https://ebay.us/tU2LAO
And here are the tools I used to do it:
Syringe to drain your valley: https://ebay.us/6gHGeA
Oven Cleaner for intake cleaning: https://ebay.us/RKM01l
Torx Sockets (you'll use the T30 a lot): https://ebay.us/xmnJdi
Long Torx Bits: https://ebay.us/TJ9C3I
Torx Screwdrivers: https://ebay.us/3gTd4B
Spline Drive Sockets (triple square): https://ebay.us/jGRBND
Allen Keys (you'll need the 5mm): https://ebay.us/896VDZ
Wet/Dry Shop Vac: https://ebay.us/k8YHyV
Mechanics Mirror: https://ebay.us/XQRbqI
27mm Deep Socket (for the fuel pressure sensor): https://ebay.us/i5YJ4F
Radiator Vacuum Tester: https://ebay.us/jJouAy
I was extremely disappointed to discover all the work in the previous video was for nought after finding the antifreeze swimming pool in the valley of the V6 engine was continuing to fill up.
I am sure replacing that broken plastic intermediate flange was worthwhile, that must have been contributing to the leak. But ultimately replacing it didn't fix the issue on my TDI.
I got a very large number of comments on the previous video highlighting that the EGR cooler bypass valve, which I'd opted not to replacing having noticed only slight discolouration on the original, is a very common cause of coolant leaks.
The design of this vacuum actuated valve means its possible for the pivoting shaft to leak, especially after 10 years and 130k miles of driving and heat cycles. Volkswagen Audi Group later revised this part, and once I'd removed my original again by taking off the intake manifold and removing the EGR cooler to access and remove it, it became apparent to me.
Although both the old and new versions of the part share exactly the same part number (059121737AM), the new version clearly has a beefed up section on the pivoting shaft. This is either to reduce the impact of heat on the seal, or its to fit a larger seal that will last longer.
My new part was stamped 2023, and my original one was stamped 2013 which lines up with he original build date of the car. If the original version lasted 130k miles, hopefully the new one will last an equal number if not more.
My previous video on this topic shows in much more detail how to remove and refit the intake manifold, which is quite a challenging process on these V6 TDI motors due to how tightly everything is packed in. I've started to get quite fast at doing it now I've figured the correct order to do things.
For more helpful how-to guides and restoration project logs, visit our blog: https://www.spannerrash.com/
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#porschecayenne #cayenne958 #3.0tdi #vag #coolant #coolantleak