1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Cleaned out my EGR at the weekend and...

Discussion in 'A3/S3/Sportback (8P Chassis)' started by RS84, Nov 23, 2010.

  1. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    ...still getting a bloody insufficient air-flow error up.

    Took out the valve and used a whole can of carb and intake cleaner cleaning it out until there was no crud left at all.

    Dropped it back in, tightened it all up and cleared the fault code. Took it for a spin and all seemed fine... couple of starts later and the emissions control system light is back on the dash grrr.

    Anyone else any experience of this?

    Are there any other components that could be bringing this error up?
    #1
  2. Ads

    Ads

    [Sep 19, 2014]

  3. Johnny Bravo
    Offline

    Johnny Bravo 6+1 Gears

    Joined:
    Jun 14, 2009
    Messages:
    807
    Likes Received:
    57
    [Nov 23, 2010]
    What error message do you get exactly?
    I had to change the EGR too because the vacuum part was broken. Now, after ~4 months, the intake flap gave up. This one is 3 times more expensive than the EGR :(
    #2
  4. c_w
    Offline

    c_w Active Member

    Joined:
    Feb 23, 2010
    Messages:
    1,058
    Likes Received:
    62
    [Nov 23, 2010]
    Is the EGR the bit on the front of the engine where the boost pipe connects?
    #3
  5. Lewis583
    Offline

    Lewis583 Active Member VCDS Map User

    Joined:
    Mar 15, 2010
    Messages:
    884
    Likes Received:
    70
    [Nov 23, 2010]
    The insufficient flow points to the valve not actually opening when requested by the ECU. Either the actuator rod is siezed or the diaphragm/vac pipe to the diaphragm is leaking.
    #4
  6. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    I don't have the code to hand here, I'll post up the ross-tech wiki link when I get home from work...

    That intake flap is notorious! I checked to make sure mine was opening and closing OK while I had the EGR off because I've read so many threads on the motor failing in it.

    Plenty of info on it here,

    http://www.audi-sport.net/vb/new-a3...manifold-flap-egr-valve-how-do-i-solve-2.html

    I think the motorsport version of the Allard EGR delete kit also removes the flap unit... Prob be a whole lot cheaper than a new one from Audi!
    #5
  7. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    The one fixed to the intake manifold with the silver exhaust feed coming into it from the right. The unit mated directly below it contains the intake flap.

    [​IMG]
    #6
  8. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    Can I test this manually? Get the hoover at it or something...

    Should I expect to see much movement from the rod?

    [​IMG]

    (That's it before the clean!)
    Last edited: Nov 23, 2010
    #7
  9. navnayyar
    Offline

    navnayyar Member

    Joined:
    Mar 23, 2008
    Messages:
    786
    Likes Received:
    0
    [Nov 23, 2010]
    I had this, couldnt be bothered in the end fixing it ad replacing it with a egr delete kit and mapping it out fixed it
    #8
  10. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    Been looking into deleting the bloody thing too.

    Did you get the EGR cylces mapped out or did they just prevent the ECU from logging that fault code?
    #9
  11. navnayyar
    Offline

    navnayyar Member

    Joined:
    Mar 23, 2008
    Messages:
    786
    Likes Received:
    0
    [Nov 23, 2010]
    Both, light and cycle
    #10
  12. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 23, 2010]
    #11
  13. ryanstewart9
    Offline

    ryanstewart9 Member

    Joined:
    Sep 5, 2009
    Messages:
    450
    Likes Received:
    7
    [Nov 23, 2010]
    Anyone know how much mapping companies normally charge to just map out the light & cycle?
    #12
  14. paddy
    Offline

    paddy Audi=No fault code, no idea

    Joined:
    Feb 6, 2008
    Messages:
    5,133
    Likes Received:
    123
    [Nov 23, 2010]
    Out of interest..if you clear a fault code it will not come back until it faults a further 3 times which is why you initially cleared it and then it came back after e few starts.
    #13
  15. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 23, 2010]
    Have you actually checked the flap itself inside to see if no teeth are broken instead of the egr.
    #14
  16. navnayyar
    Offline

    navnayyar Member

    Joined:
    Mar 23, 2008
    Messages:
    786
    Likes Received:
    0
    [Nov 23, 2010]
    Last edited: Nov 23, 2010
    #15
  17. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 24, 2010]
    Useful to know, thanks.

    The flap on mine seems to be working fine, just the EGR I'm having trouble with. As was said below it's either the rod has seized or the diaphragm ist kaput... I'll have to take it out again for a look :( a couple of those bolts at the back are a nightmare to get at!

    If the motor in the flap has failed it throws its own seperate fault code. It's somewhere in the thread link I posted earlier.
    #16
  18. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 24, 2010]
    I didnt say it failed, I said the teeth may of broken & it functions sometimes ok, this has happened to others BTW, thus fault code thrown about insufficient air, worth a look anyway to be sure as these have been very unreliable, you may have the updated one already, something to discount.
    #17
  19. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 24, 2010]
    Ah sorry, I see. Yeah certainly can't harm to have a look. Is it easy to take the cover off the motor without damaging it?

    Any idea where the sensor that logs the fault in question is?
    #18
  20. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 24, 2010]
    Yeah fairly easy to remove, its only a pressured plate, just lever edges up, have a looksy inside, then push back on & tap the corners back over with a hammer gently, job done.

    There's a sensor on the IC piping just behind the rad, maybe its this.
    #19
  21. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 24, 2010]
    Actually thinking about it now, when I took the EGR out the IMF was open... surely it should have been closed if the engine wasn't running?
    #20
  22. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 25, 2010]
    Anyone?
    #21
  23. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 25, 2010]
    Ok have you actually checked the egr flap/actuator at rear of engine as this maybe is getting stuck.
    #22
  24. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 25, 2010]
    I checked the flap in the IMF when I had the EGR out, but I only pushed it down a couple of times. The flap was open, and returned to the open position each time. No real resistance on it. I suppose if there are only a couple of teeth broken on the cog it would only fail 1 or 2 times per rotation.

    Should the flap be in the closed position when the engine is off?
    #23
  25. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 25, 2010]
    Please read my post again mate.
    #24
  26. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 25, 2010]
    Sorry NHN I must be misunderstanding you!

    When you say egr flap/actuator do you mean the rod in the EGR or the flap in the IMF?

    Apologies for the ignorance and thank you for the help so far!
    #25
  27. NHN
    Offline

    NHN Retrofitter - Audi - VW - Skoda - Seat Site Sponsor VCDS Map User

    Joined:
    Jan 14, 2008
    Messages:
    27,320
    Likes Received:
    1,229
    [Nov 25, 2010]
    The egr unit itself is at the front, my post advised to check the egr flap/actuator thats at the rear of the engine, there's an egr cooler iirc on bkd's anyway that supplies the egr at the front through that inch or so thick pipe to the right. in one of the pics above, maybe this is getting stuck.
    #26
  28. RS84
    Offline

    RS84 R15 - TDI Power

    Joined:
    Mar 15, 2008
    Messages:
    168
    Likes Received:
    1
    [Nov 25, 2010]
    Ah I follow, cheers mate!

    I just assumed that pipe was a straight feed from the exhaust manifold without any valves etc.

    Didn't know the recirculated gases were cooled either!
    #27
  29. a3glenn
    Offline

    a3glenn 6th gear

    Joined:
    Jan 17, 2010
    Messages:
    95
    Likes Received:
    3
    [Nov 26, 2010]
    for sure it is a EGR valve broke, same fault on mine, if you suck on the vac pipe there will be no resistance (air leak) same withe the error codes, cleared them the came back a day later

    change your egr
    #28

Share This Page