Hmmm thanks for the suggestion to try the EGR cleaning kit from Geno's garage. I was thinking about the bypass valve, and to me, it does not make sense that it would by itself be leaking. Like you said, it has to be a gasket.
I will try the EGR cleaning kit from Geno's. Replace all the gaskets plus the CCV filter. I'll update here on how that goes in a few weeks.
One of the review on the 07-12 EGR cleaning kit page on Geno's mentions that the "back nuts" have to be torqued to 85ft lbs because he was smelling exhaust after doing the kit. Tightening to 85ft lbs fixed this issue. Can you explain where the "back nuts" are, since you have done this yourself as well.
Yea the back nuts on the cooler are know to be a little bit of a pain, I have taken my cooler off twice now, I didnít think it was that bad though. People talk about all the contraptions they made up to get them back on on, I donít get it. I just jammed my arm back there and put it on with my fingers. Laid up on top the motor, left arm went in from behind the cooler to the back right nut. Took me 1 try and just about a minute to do. Getting the right combo of socket and extension length to reach the nut but fit under the cowl was the hard part IMO. As for 85#, I didnít torque mine, I couldnít get my T-wrench back there, I just put it on good and tight with my socket wrench and itís been just fine. You will see leaks easy, there will be black soot blowing out of the leak haha. The rear trick there is to use the new gaskets from the Genos kit, itís like 4-5 layers where stock was 2 layers. The kit gasket seals up much much better.
Now that Iím deleted, I still decided leaving the EGR system in place was best for me. It makes returning to stock much easier down the road if needed. I just run it ďdisabledĒ with the exhaust parts removed/deleted. So a good service and new gaskets wonít h be a waste of your time, even thought I was deleting. I wonít be doing it often though since itís not even used. So it stays, at least until my stock turbo bites the dust, then upgrade might be in order and the EGR wonít hook up to a 2nd gen swap.
When you do the service, use purple power cleaner, I soaked my cooler and egr valve in purple power for about 12 house, and it came out clean as new when I rinsed it out. I didnít bother ďair blowing it outĒ first, I didnít want the soot in the air, I went straight to water hose in the grass to get the loose stuff off then sent it to the purple bath in a bucket.
Ohh also, if the cooler is intact, itís important that you bleed the cooling system right. There is a ďhigh pointĒ vent coolant riser thing. You canít miss it. Make sure you squeeze the top radiator hose and get the air out of that vent, coolant should come out when topped off. Then check it again a few days later. Any air in the cooler will make it crack and dump coolant into the exhaust. Iím pretty sure this is the reasons that vent is on there.. ***the vent plug can be very hard to remove, DONT STRIP IT! (personal experience here) it needs heat. I suggest you break it free one day when you just shut down from a full temp drive, then later when itís cool and you go to service the egr you can get it off. Otherwise use a torch to heat it up.