EGR Error 99.2%

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Sha170

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Hi, Ive got a 1.6 tdi which struggles to start.
It will start first time and idle rough until warmed up.
If i switch off before its warm it will not start again for a few hours.
It starts perfectly fine when warm.

When I try start it again from cold or let it cool down after its warm it wont start.
Ive read about how common the EGR fault is on this engine and they can cause problems starting when it is stuck "open"

Ive plugged in VCDS and gone onto live data.
The car which wont start and keeps cranking is showing EGR Error as 99.2%
What does this mean?
 
Have you got a coil light on and if you could drive it I'm guessing you get loss of power,

At a guess I would say your egr valve(cooler) is knackered very very very common to the point that I think VW are doing these as good will even out or warranty

however if you don't get it done under warranty make sure who ever does the job carrys out a software update of you will back in the same position but £600 lighter
 
biscuit-a3 said:
Have you got a coil light on and if you could drive it I'm guessing you get loss of power,

At a guess I would say your egr valve(cooler) is knackered very very very common to the point that I think VW are doing these as good will even out or warranty

however if you don't get it done under warranty make sure who ever does the job carrys out a software update of you will back in the same position but £600 lighter
Click to expand...
Coil light does come on however it shows an "7336 Unknown error and 7332 Unknown error"
It seems as if the car only struggles mainly on a cold start.
I dont think its anything to do with EGR?
 
What are you using to check the fault codes ??. Has the car been remapped / had the DPF removed.

Karl.
 
Are you using a genuine lead with the latest software ?
If it's a genuine lead check that the software is upto date. If it's a clone lead thats your problem .
If it's a Genuine lead with the latest software then you can contact tech support and they will instriuct you in how to download some files for them to check.
As new modules appear they rely on people providing data back to them from the new cars.

Karl.
 
IMG 2894 Also i noticed this pipe has been cut, would you happen to know what it is for?
 
Thanks for the replies.
I've had the car looked at by a mechanic who used vcds. He has blanked off the egr.

The car is still exactly the same, struggles to start and throws out White smoke which the mechanic said is diesel.
He has checked the sensors and says they are fine.
The cars fan stays on now even on a cold engine.

He has recommend I show the car to an auto electrician.
What advice would you guys give?
 
White smoke on start up this time of the year with poor running for the first 30 seconds or so could well be glow plugs or lack of them. Check the reading on the coolant temp sensor. If this goes too high the fans will kick in and the glow plugs would not be enabled when the engine was being started.
Why did the mechanic block the EGR, You are liable to get a check engine light unless it has been mapped out as the ECU will see a problem.

Karl.
 
desertstorm said:
White smoke on start up this time of the year with poor running for the first 30 seconds or so could well be glow plugs or lack of them. Check the reading on the coolant temp sensor. If this goes too high the fans will kick in and the glow plugs would not be enabled when the engine was being started.
Why did the mechanic block the EGR, You are liable to get a check engine light unless it has been mapped out as the ECU will see a problem.

Karl.
Click to expand...

The White smoke problem has been there before the cold wether kicked in. I read that the glow plugs only kick in under 3 degrees, I am pretty sure they are not the problem.

The problem is some sort of overfuelling? If the car is switched off and I try to restart while cold it won't start again for a while. As if its getting flooded with fuel/ lacking fuel or air?
Once warm the car drives like it should.


I will check the coolant sensor temp. The fans kicking in is a new problem, I don't think that contributes to the start up.

EGR was mapped out, as I'd been told this was the cause of the non start up however the car is still the same and the engine light has now come back on so I will get it scanned again and see what it shows.
 
Another thought is the car trying to regenerate? , is the DPF blocked ?. White smoke is a sign of DPF issues sometimes, extra fuel is injected to burn in the DPF to heat it up.
Check the stats in VCDS for the DPF differential pressure and soot loading.
The fans run when the car is regenerating, they did on my A4 when it was parked up at least anyway.

Karl.
 
desertstorm said:
Another thought is the car trying to regenerate? , is the DPF blocked ?. White smoke is a sign of DPF issues sometimes, extra fuel is injected to burn in the DPF to heat it up.
Check the stats in VCDS for the DPF differential pressure and soot loading.
The fans run when the car is regenerating, they did on my A4 when it was parked up at least anyway.

Karl.
Click to expand...
It's not DPF either as this has been mapped out and removed.
 
audi upgrades




I have made two videos of the problem. In the first video the car starts and can be heard that it is very rough.
In the second video, thats when the car is struggling to start but is jumping and eventually starts. This isnt always what happens, many times it doesn't start.
In the second video you can see the white smoke it throws out, according to a mechanic its diesel.

The EGR and DPF have been mapped out so these cannot be the issues causing the start up, any advice will be appreciated.
 
So the DPF was removed from the car, cut open and the innards smashed out. welded back and put back on the car ??
Have you checked the cam timing ?. On VCDS you can check the cam timing with the 1.9tdi it's called the torsional value.
Not 100% sure what it is on the 1.6 TDI, Sounds to me like it's out. When I had my Passat and played with the timing advancing and retarding it you got a similar kind of problem when you went too far. Diesels are very funny about cam timing.
The white smoke is unburnt diesel that has been injected whilst it's turning over , as soon as it fires the diesel in the exhaust is vapourised into white smoke.
The red arrows inject diesel into the jet pipe of the aircraft to make smoke, they color it red or blue to make different colors, same principle.

Karl.
 
when you say it struggles to start , how long have you owned the car ? did it struggle to start when you bought it ? the egr is at 99.2 % as this is what it will read when its mapped out .nearly closed at all times .
doesnt actually mean it is closed could be broken . as you dont have to blank them off . try removing egr valve itself it could be full of carbon . if it is then it will struggle to start and tries to fire through the inlet instead
 
desertstorm said:
So the DPF was removed from the car, cut open and the innards smashed out. welded back and put back on the car ??
Have you checked the cam timing ?. On VCDS you can check the cam timing with the 1.9tdi it's called the torsional value.
Not 100% sure what it is on the 1.6 TDI, Sounds to me like it's out. When I had my Passat and played with the timing advancing and retarding it you got a similar kind of problem when you went too far. Diesels are very funny about cam timing.
The white smoke is unburnt diesel that has been injected whilst it's turning over , as soon as it fires the diesel in the exhaust is vapourised into white smoke.
The red arrows inject diesel into the jet pipe of the aircraft to make smoke, they color it red or blue to make different colors, same principle.

Karl.
Click to expand...

Yes the DPF was removed smashed out and welded and put back on the car, the ecu was mapped according to this.
Im not sure about the cam timing, but if this was the cause then would it disappear when the car is warm?

hollow said:
when you say it struggles to start , how long have you owned the car ? did it struggle to start when you bought it ? the egr is at 99.2 % as this is what it will read when its mapped out .nearly closed at all times .
doesnt actually mean it is closed could be broken . as you dont have to blank them off . try removing egr valve itself it could be full of carbon . if it is then it will struggle to start and tries to fire through the inlet instead
Click to expand...

Ive owned it a month, I got it with this problem. I believe the EGR may have been changed last year to try and fix this problem but it made no diffrence, i only say this because I found a box with the part number on it matching a new EGR in the boot.
Ive had the EGR blanked off in the hope it would either fix the problem or at least EGR would be eliminated.

If the injectors were the problem, would these bring up an error code?
The engine light is still on showing "unknown error fault" and the glowplug light flashes after about 10 minutes and gives the error "start/stop is currently available"
 
Could it be something in the map? Is it a proper custom map or a generic one to code the EGR and DPF out?
 
Get the cam timing checked next time it's on VCDS but with a very unknown past and the unknown errors you are seeing it sounds like the ECU map may not be correct. And if the car doesn't support stop/start then I would definately say the ECU map is not correct.
 
desertstorm said:
Get the cam timing checked next time it's on VCDS but with a very unknown past and the unknown errors you are seeing it sounds like the ECU map may not be correct. And if the car doesn't support stop/start then I would definately say the ECU map is not correct.
Click to expand...

I have access to VCDS how would I go about checking the cam timing?
Unsure if the car had a map on it previously, but I know it has now with the EGR and DPF mapped out. I doubt the map is causing the problem. Could the map really cause the problems in the videos?
 
In the measuring blocks for the engine look for synchronous angle or torsion value.
Has your car got stop /start ?

Karl
 
desertstorm said:
In the measuring blocks for the engine look for synchronous angle or torsion value.
Has your car got stop /start ?

Karl
Click to expand...
Will have a look at this, will it show for my engine, common rail?
Also i believe its the same procedure for checking the injectors?

If it was either the cam timing or injectors, should this problem still affect the car when its warm?

Yes it is supposed to have stop start which works for the first 5/10 miles until the glowplug light starts flashing and throws the message "Stop start currently unavailable" However if i turn the car off and back on the light goes off and it starts working again/
 
When I attempt to measure engine measuring blocks it does not let me.

I click on Engine > Then adaptation, but that box is blank and does not let me click it?
 
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