Update,
I tried a can of Wynn's turbo cleaner on the intake side, did the same long drive and exactly the same set of symptoms. I logged it this time with VCDS for those who are interested, screen shots below. I have a 2-stage cleaning product coming to do the exhaust side this week - I'll...
Update,
During investigation I found the valve head had fallen off the EGR valve shaft which caused the cough and stall and subsequent failure to start.
Great, so I replaced the whole EGR valve, started up first time. I did a long drive today, full array of driving conditions, windy roads...
I replaced the DPF about 20,000 miles ago with a pattern part and brand new pressure lines and switch. it has been working seamlessly since. The turbo I replaced around 90,000 miles ago, again, perfect operation for all those miles. I do around 800 miles a week in the car but all motorway...
So,
I recently got a P0401 Exhaust Gas Recirculation (EGR) System: Insufficient Flow Detected.
Stripped and cleaned the EGR but mil light returned on test drive. When I cleared the fault when warm, mil light did not return during several hours of driving until cold start. Then back on...
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