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  1. #1
    Reverse Gear

    Join Date
    Jul 2010

    Smile A4 2.0TDI EGR error after remap.....help and advice sought!!!!

    Audi A4 2.0TDI 140BHP 2006 model, B7 shape, BRE engine

    The car has had a full s/steel exhaust system fitted, including decat.
    The manifold had been taken out and fully cleaned of all gunk/soot (about 18 months ago now and I do 12k miles a year)
    I uploaded a Stage2 Superchips remap to the car via my Bluefin device.
    The car ran great, smooth power, no issues.
    I had the EGR system blanked off using blanking plates
    I swapped to a Stage2 Superchips ‘EGR delete’ remap.
    The car ran smoothly but an error on the dash appeared, despite the EGR delete remap.

    Several months later, the car started to stutter during acceleration.
    It sounded like a breathing issue. I had the turbo checked for problems but there was no play in the turbo.
    I decided to unblank the EGR system and reverted to the original Stage2 remap.
    The EGR error still showed on the dash (EGR insufficient flow, according to VAGcom)
    I removed the remap and reverted to standard map.
    Despite the loss of power and urgency, the car was still hesitant during acceleration but there was no EGR error.

    I put the Stage2 map back on and the EGR light reappeared and the hesitancy during acceleration became more pronounced, presumably because of the increased demand on airflow, etc.
    I removed the remap and reverted to standard map and the EGR light disappeared but hesitancy was still apparent (to a lesser degree) on acceleration.

    With the help of a friend who works at Audi, we have replaced one-by-one the below components:
    1. Replace EGR main body
    2. Replace MAF sensor and replace K&N filter with OEM paper filter, in case hot oil from the K&N had degraded the MAF filament.
    3. Replace vacuum plunger unit attached to throttle, as rubber seal had a small split
    4. Checked the exhaust system for splits/signs of damage.

    The car still has the stuttering/hesitance on acceleration, although it does seem a little improved. When on standard map, no dash error appears, when I put the Stage2 map back on, I get the EGR error again. Stuttering is more noticeable when remapped, although a little better than it used to be.
    Have any of you guys got any ideas on this one or anything that I should check? Has anyone had similar problems? Thanks in advance for your support

    All the best, Dave

  2. # ADS
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  3. #2
    Reverse Gear

    Join Date
    Jul 2011
    What sort of rev range? and is this under light or heavy acceleration?

  4. #3

    Join Date
    Sep 2011
    Have a 140 tdi that has been chipped to 210 when bought, i do feel a slight hesitance in slow traffic but i have put this down to what gear you are in as the car just want's to rev and go, foot down it flies. I have to take out for a blast now and then as it only does 3k per year. Car has only done 50k on a 57 plate.



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