EGR valve?

[bloostar]

My car's gone into limp mode again. Judging by the other posts, it looks like it is the egr valve. Fault codes from vcds are P0403 and P0408 (not at house so can't post full scan). There is a funny ticking noise from the rear exhaust pipe and a nasty mechanical sound from the egr near the manifold (intermittent). When engine is turned off, there's also a final whooshing noise. Oh, and my esp light has come on now however I think it's because I pulled a fuse out to check so unrelated. Off to garage tomorrow but just wanted to check if this sounds familiar or if its more terminal! Engine otherwise sounds ok.

Just what I wanted for the weekend!!

[Guest 2]

Hopefully these will give some insight

16787/P0403/001027 - Ross-Tech Wiki

16792/P0408/001032 - Ross-Tech Wiki

[bloostar]

Thanks, the Ross Tech site was next on my to do list :-) Here's the vcds for info, although I think it speaks for itself..


00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
07-Control Head -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
0E-Media Player 1 -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
1E-Media Player 2 -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
37-Navigation -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
4F-Centr. Electr. II -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: OK 0000
56-Radio -- Status: OK 0000
61-Battery Regul. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-016-BLB.clb
Part No SW: 03G 906 016 HS HW: 03G 906 016 HS
Component: R4 2,0L EDC G000SG 9673
Revision: --H02--- Serial number:
Coding: 0000072
Shop #: WSC 02335 785 00200
VCID: 7BF3C1273A2AC3C0759

2 Faults Found:
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 24
Mileage: 140962 km
Time Indication: 0
Date: 2013.07.19
Time: 17:20:14

Freeze Frame:
RPM: 1176 /min
Speed: 0.0 km/h
Duty Cycle: 40.2 %
Voltage: 13.68 V
Mass Air / Rev.: 445.0 mg/str
Duty Cycle: 0.0 %
Bin. Bits: 00000000

001032 - EGR Potentiometer (G212)
P0408 - 000 - Signal too High - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 20
Mileage: 140964 km
Time Indication: 0
Date: 2013.07.19
Time: 17:31:39

Freeze Frame:
RPM: 2415 /min
Speed: 74.0 km/h
Load: 14.1 %
Lambda: -10.9 %
Mass Air / Rev.: 365.0 mg/str
Mass Air / Rev.: 450.0 mg/str
Bin. Bits: 00000000

Readiness: 1 1 0 0 0

It's definitely running rough so I think it must be the valve rather than the potentiometer. Dang! £200 on ECP give or take however I think I'm going to leave it to the garage, assuming that's all that's wrong... Still can't get the ESP light off now either! aaggH!! I was just commenting on how reliable my car had been the other day as well.. Let you know how I get on next week. Ta very much.

[gupsterg]

Something I read about that fault code ...

I pulled and cleaned the EGR last night (and cleaned all of the electrical connections) -- it was a mess. My suspicion was that carbon build-up on the shaft was keeping it from travelling freely, and since it's motor driven that it was causing the high signal on the potentiometer when it couldn't move.

Perhaps try a clean before replace? also you can actuate the EGR via VCDS 'output test' in module 1 with engine not running and unit unmounted but harness connected ...

[bloostar]

I was considering cleaning however it is looking (and sounding) pretty terminal. Although I'm ok with general servicing stuff I'm a bit loathed to touch this thing as it's a bit beyond my ken tbh. Maybe if it wasn't such an important car I rely on every day I'd fire right in there but I'm going to just bite the billing bullet and let the garage sort it this time.. With the engine off you can hear it tapping away loudly for a few secs, as though the thing is trying to work. With engine on, it sounds like a machine gun. I think something has come loose although I'll try the output tests as it might be the potentiometer just going bananas... Never thought of that but I'm a bit of a vcds newbie, although at least I won't get ripped off if I know what's wrong beforehand. I did also call out the AA and he found a code (p0404) which strangely wasn't showing on my vcds scan??!

Thanks guys, I'm left with a 15yo clapped out v6 jag with less power than my broken 2.0 tdi baby for a few days at least... My ESP light is out now thankfully, so only one bill to worry about for now.

[gupsterg]

Hi mate ...

In the past I've only done normal service items on a car and my car really popped my cherry! concerning that ... ...

The EGR is mounted in a easy access area from stuff I've seen and I think JimC64 cleaned his on a 2.0 TDi ...
This post of his has some great threads with media Link:- A6 EGR location & removal "how to?" - Page 2

Besides the linked info by Jim PM an external email will send you stuff to digest and decide ...
I believe if you can do the brakes you'll easily manage the EGR ...

[bloostar]

Right, wish my cherry good popping luck! I can always call the AA again if I screw up. Lol Looks like my cheap (but good German build quality) Lidl tool kit has all the correct torx bits so I'll take a crack once I get the new gasket set. Watch this space for lots of swearing and chaffed fingers. Going to order a decent Famex toolkit as well as my ratchet just blew up too.. It's all happening in threes this weekend!!

[1966baz]

Sounds like it is s fairly common fault . My EGR valve was covered in soot so cleaned it and the fault code still came up. The nylon wheel was worn and thus spinning and not engaging causing intermittent lack of power. Anyway new valve fitted so hope there will be no more problems. Cheers Nick.

[bloostar]

Egr is now off... Forgot to take pics unfortunately. Competely disintegrated and so a new one required - already away in the bin collection too. I' m thinking this might be related to the juddering at cold I've been experiencing the last 12 to 18 months. We'll soon see when the new one's fitted on Thursday. Consider my cherry well and truly popped though, thanks for the support!. Now to check out the drop links as they're also showing wear and tear...

[1966baz]

Good luck with the new valve. I think this should cure it. Cheers Nick.