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EGR insufficient flow

141K views 146 replies 31 participants last post by  JetForce  
#1 ·
Hi All,

Been enjoying my 3.0tdi immensely since i bought it last November and have covered about 6k miles in it during that period, its just clicked over 59k in total. Really is the best car i've ever owned. Yesterday the check engine or emission control light came on, so i got the RAC out to read the code since Audi wanted ÂŁ138 (!).

Its come out as EGR Insufficient Flow Detected. The light is out and i've driven home tonight about 40 miles (mostly fast motorway) and all is well, however i'm inclined to see whether i can clean out the EGR valve as i've read they get clogged up with soot. I have a workshop guide but it doesn't really cover whether it can be cleaned out or not, so any experiences or advice would be greatly appreciated!

Thanks guys
 
#4 ·
My EGR valve failed at 47k. Dealer replaced at a cost of ÂŁ950! They said it is difficult to get to as it's buried in the vee block under the inlet manifold.

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#5 ·
Dan my friend first of all sorry about my rudenes because i didnt told you the latest news about my troubles! As it turns out EGR isnt that much of a big deal to take apart and clean... It is in the middle of engine maybe a bit more at the drivers side you can see that the iron pipe hose is conected to it from the intake manifold. It isnt the easyest job but it isnt so dificult as wel... In my case it wasnt so cloged we cleaned with the brake cleener spray and put it back in place... Two hour work at max!
 
#10 ·
That's interesting zlaja. Thanks for the info. I'm glad I managed to get audi uk to pay half the bill then! If it happens again, I know I can likely resolve myself.

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#12 ·
Just incase anyone's interested, I took off the throttle control valve, upper manifold, left-hand lower manifold and EGR to Intake manifold pipe at the weekend. All completely full of crap.
Throttle control value full of oily carbony gunk (though cog in motor was fine)
Upper manifold full of oily crap
lower intake manifold had about 3-5mm of oily/carbon gunk that had settled all around and on the swirl flaps.
Cleaned everything and put back together. Also checked the air filter and as i removed it, it was apparent that the intake duct was blocked with leaves and all sorts of rubbish. So i've cleaned it and ordered a new one.
Seems to be running a bit sweeter, but still detecting a very very slight wobble at idle, however i have the other lower intake manifold to do which i hope will improve things further.

Cannot believe how much crap accumulates - cars only done 59k, but methinks it's spent a lot of time in traffic.
 
#13 ·
There is TPI for this, so Audi service should do it for free even it's out of warranty. Or You can use VCDS for "burning" of EGR, but it must be CCWA engine type.
 
#16 ·
+1. Yes, tutorial please. I'm certainly not going to pay Audi in another 40k miles to do mine again. Wish I'd had the bottle to diy mine the first time round!

Question @ tomwilliams: Did you replace all the manifold gaskets with new ones?
 
#18 ·
Good stuff, cheers Tom. Look forward to that.

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#21 ·
To review the topic I started cleaning and fixing my intake manifold! First to say the problem with the manifold is a joke! They are so shameless charging all that money for a problem like this! Maybe i cant express myself in the right way but belive me i will make a video for you explaning the problem and you will see what i was talking about! Be patient for a couple of days and never pay them big money for your intake manifold problem! This is the picture of cleaning the damn thing,more pics and videos will come
 
#22 ·
Video eagerly anticipated! And 'NO', I will never pay the stealer to do this job again, if it's as straightforward as you say!

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#23 · (Edited)
http://www.youtube.com/watch?v=hL4VwMKO0Pg&feature=youtube_gdata_player

Ok guys this is the first video this is the right side intake manifold an itbwas cleaned before dont let that its cleannes confuse you,it was all dirty and cloged before... Problem with it is that the little plastic bits that hold the axel centered are worn out and the axel as you can se is pretty loose wich cause the flaps to let some air pass by them and creates a problem... Now what i am trying to do is to find someone who is able to take the mold of that little plastic bit and cast it out of metal! If i sucseed i will inform you and i am sure that in your countries it is much bigger chance to find someone to do such a thing! Because i alredy replaced this right side intake with a new OEM one i have this on a video as a spare so i can play with it. Now i started having problems with my left side and what i am trying to do is to save money and find a way to fix that left side... More pics and info will come soon! Cheers

Edit: one more thing,if you decide to do this by yourself you can easly do it and you also dont need new gasket set cause mine was on a car for 120.000km and they are in perfect nick!
 
#24 ·
Excellent stuff, would love to see a video on how to remove these components from the engine....keep up the good work ;-)
 
#26 ·
I've already fixed this at the dealership and payed a lot of money for it, but still, I am very interested in this. So, please, keep us posted! :)