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Info: 3.0L TDI Diesel EGR Cooler data

7.3K views 24 replies 6 participants last post by  ToolmanJohn  
It's probably going to leak again even with sealant if you don't figure out and fix why it leaked. Could one of the surfaces be warped/non-flat? Usually these kind of gaskets are highly reusable, but once they leak they get pretty deformed or gouged and really need to be replaced. I think there is a lot of heat and pressure on this gasket. You may be able to fabricate a new gasket using the old one as a template, by cutting out material with an x-acto knife. Look for a sheet of "High Temperature Automotive Gasket Material" in the same thickness as your gasket, and also use anaerobic sealer.

Have you looked into ordering it directly from VW?
 
Bummer it's gone, so I guess this doesn't apply anymore, but I want to say this anyways: The guy that mentored me in VW diesel mechanics, says this type of metal gasket can be reused indefinately with a fresh coating of hylomar sealant each time. He even does this with steel head gaskets on VW diesels. The only thing that concerns me in this case is that, since it was already leaking, there is likely metal erosion on the gasket and/or sealing surfaces.
 
What I don't get is why they use this kind of seal, which is so thinly coated, and almost designed to start leaking.
These gaskets are much more durable than fiber, etc. gaskets as long as both surfaces are smooth, flat, and clamped tightly. They can handle much higher heat and pressure, but cannot absorb as much movement, e.g. from parts warping. I would probably clean and reuse w/ hylomar if the old gasket didn't fail, if it did, you need to check the surface flatness and use a new gasket. If the rubber coating still looks good, you can even skip the hylomar likely. A used gasket that didn't fail is okay too.
 
Like I said above, a new gasket probably won't help anyways, it won't have leaked for no reason. If you can confirm the surfaces are clean and not warped, it should be possible to make or have made a custom gasket. Any company that makes custom MLS head gaskets for race cars should be able to do it. Although, it would probably be cheaper and easier to just swap to the other EGR you can get a gasket for.