I got a used mk3 egr cooler from eBay , After cleaning , I noticed the top coolant pipe edge little bent , while trying to fix this , I may have made it a little worse not much , Does the pipe have to be perfectly round for water tight , I can always reuse my old one , was trying to save time I am having trouble uploading image
thanks for reply you kno I checked & can get to the rear both bolt nut of cooler without cowl removal Do you think I can get away without removing cowl It’s aright hand drive & still figuring access to that bolt from hell Thanks
Not sure. With left hand drive it's more-or-less necessity. It will make it easier. Might as well try without removal first though. That you can do before getting into anything else, even days in advance. And just leave it off. If you can manage to back out the stud at that location even better: then the studs at the rearmost connection don't have to come off, and they'll tend to hold the gasket in place as you lift the cooler out. For the stud you need an E8 Torx socket, likely 1/4" drive. Use a small ratchet, just reach in there, it'll be pretty much one click at a time (due to limitted room), and you want to go real slow; the stud is steel and the head is aluminum, so it's a little glued in there. Don't rush; you don't want to round off the head. You will need to loosen the gas tank vapour return tube bracket that passes over top of the egr components, lift it up slightly for clearance. See first two links in my signature, for tool list, tips, relevant repair manual excerpts (torque values and so on). On a phone turn it landscape to see signature.
