2006 A6 2.0 tdi egr fault

[brian.n]

my car is a 2006 A6 2.0 tdi BRE engine code .

went into limp mode last week and brought up a EML on dashboard.

scanned it with VCDS and the following faults were logged.



Address 01: Engine Labels: 03G-906-016-BLB.clb
Control Module Part Number: 03G 906 016 HS HW: 028 101 255 7
Component and/or Version: R4 2,0L EDC G000SG 9673
Software Coding: 0000072
Work Shop Code: WSC 00353 210 82099
VCID: 7BF5E6813AAB6CC6CE5-802E
3 Faults Found:

001032 - EGR Sensor 2
P0408 - 000 - Signal too High - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 15
Reset counter: 255
Mileage: 245387 km
Time Indication: 0
Date: 2014.04.29
Time: 15:27:23

Freeze Frame:
RPM: 2268 /min
Speed: 69.0 km/h
Load: 38.4 %
Lambda: -1.8 %
Mass Air / Rev.: 705.0 mg/str
Mass Air / Rev.: 945.0 mg/str
Bin. Bits: 00000000

001027 - EGR Valve (N18)
P0403 - 000 - Malfunction
Freeze Frame:
Fault Status: 01110000
Fault Priority: 2
Fault Frequency: 178
Reset counter: 255
Mileage: 245407 km
Time Indication: 0
Date: 2014.05.01
Time: 11:23:11

Freeze Frame:
RPM: 1134 /min
Speed: 17.0 km/h
Duty Cycle: 84.4 %
Voltage: 13.45 V
Mass Air / Rev.: 550.0 mg/str
Duty Cycle: 0.0 %
Bin. Bits: 00000000

001025 - EGR System
P0401 - 000 - Insufficient Flow
Freeze Frame:
Fault Status: 01110000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 245439 km
Time Indication: 0
Date: 2014.05.02
Time: 11:24:46

Freeze Frame:
RPM: 1806 /min
Speed: 15.0 km/h
Load: 17.6 %
Duty Cycle: 14.5 %
Duty Cycle: 94.1 %
Mass Air / Rev.: 390.0 mg/str
Mass Air / Rev.: 650.0 mg/str


Readiness: 1 2 0 0 0

so i cleared all faults and went for a drive, drove much better but still with occasional flat spots . EML did not return.

re scanned again, this time 2 faults.


Address 01: Engine Labels: 03G-906-016-BLB.clb
Control Module Part Number: 03G 906 016 HS HW: 028 101 255 7
Component and/or Version: R4 2,0L EDC G000SG 9673
Software Coding: 0000072
Work Shop Code: WSC 00353 210 82099
VCID: 7BF5E6813AAB6CC6CE5-802E
2 Faults Found:

001025 - EGR System
P0401 - 000 - Insufficient Flow
Freeze Frame:
Fault Status: 01100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 245567 km
Time Indication: 0
Date: 2014.05.06
Time: 21:45:24

Freeze Frame:
RPM: 1407 /min
Speed: 0.0 km/h
Load: 9.8 %
Duty Cycle: 14.5 %
Duty Cycle: 94.1 %
Mass Air / Rev.: 390.0 mg/str
Mass Air / Rev.: 595.0 mg/str

001027 - EGR Valve (N18)
P0403 - 000 - Malfunction - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 15
Reset counter: 255
Mileage: 245567 km
Time Indication: 0
Date: 2014.05.06
Time: 21:45:39

Freeze Frame:
RPM: 1407 /min
Speed: 0.0 km/h
Duty Cycle: 84.4 %
Voltage: 13.30 V
Mass Air / Rev.: 585.0 mg/str
Duty Cycle: 0.0 %
Bin. Bits: 00000000


Readiness: 0 0 1 1 1

obviously a problom with the egr valve, im going to remove and clean it tomorrow but ive read that cleaning the type on my car does,nt work and that it should just be replaced? anyone know if thisis correct?
[FONT=Lucida Grande, Trebuchet MS, Helvetica, Arial, sans-serif]i did initially think it was the anti shudder valve/ IMF that was the problem but no fault codes have come up for it. thoughts?[/FONT]

 

[B5NUT]

I know someone who has just had to replace his EGR due to the teeth on the plastic gears had start to strip, and caused the same fault codes as your first scan. Only option was to the replace the EGR unit.

 

[brian.n]

I know someone who has just had to replace his EGR due to the teeth on the plastic gears had start to strip, and caused the same fault codes as your first scan. Only option was to the replace the EGR unit.

cheers for the swift reply,
yes i have heard a similar story in that the soot build up puts stress on the drive gears and they eventually break or strip,
also my local main dealer told me they just have to be replaced when faulty, cleaning wont cure the problom but they would say that i suppose.

 

[B5NUT]

Cleaning will prevent the teeth from stripping, but once stripped a new unit is required, as you cannot buy the gears. Best is to open up the side were the gears are and take a look. It takes very few tools to remove the EGR very much a DIY job.

 

[brian.n]

Cleaning will prevent the teeth from stripping, but once stripped a new unit is required, as you cannot buy the gears. Best is to open up the side were the gears are and take a look. It takes very few tools to remove the EGR very much a DIY job.

im going to remove it at the weekend and open up the drive housing to see whats going on, ill post my findings , thanks.

 

[S3AMK20VT]

just get it coded/remapped out and if you want fit a blaking plate or egr delete kit

 

[brian.n]

So i removed the asv and egr valves this evening. The asv looks fine, butterfly moving smoothly throughout its travel.
Egr valve drive is damaged though.

Stripped teeth clear to see there.
So i guess ill have to buy a new one, darkside developments are the cheapest ive found online for a new one so far.

As regards a egr delete kit i would do this were it not for the fact of the re map issue,
Is it possible to do this with vcds as i have just bought the pro kit and could do it myself with a bit of guidance.

 

[B5NUT]

You would need a new ECU MAP to delete the EGR, and VCDS cannot write map files to the ECU.