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EGR insufficient flow

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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!

Sent from my BlackBerry using Tapatalk
 
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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 ;-)
 
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#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! :)
 
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#31 ·
Yap thats the error and i think flap bank 1 is right side of the car looking from a drivers position thing you should do is to take off the plastic cover and observe the flaps position when the car is off right side should be down and left should be up! When you start the cars flaps move in opostite direction... You will notice that one of them isnt working and its stucked! The one that is stucked (in your case probably right) remains in down position. Just push it up with your finger or a screwdriver and it should go up! More better solution is to tie it with a plastic zip string if you know what i mean so that cant go totaly down when car is off. My car worked like that for a year without problems!
In case you dont know those flaps are located left and right on top of engine somewhere in line with the turbo
 
#32 ·
zlaja011 said:
Yap thats the error and i think flap bank 1 is right side of the car looking from a drivers position thing you should do is to take off the plastic cover and observe the flaps position when the car is off right side should be down and left should be up! When you start the cars flaps move in opostite direction... You will notice that one of them isnt working and its stucked! The one that is stucked (in your case probably right) remains in down position. Just push it up with your finger or a screwdriver and it should go up! More better solution is to tie it with a plastic zip string if you know what i mean so that cant go totaly down when car is off. My car worked like that for a year without problems!
In case you dont know those flaps are located left and right on top of engine somewhere in line with the turbo
Click to expand...
thanks for replay
As I know the flaps are located in the intake manifold
So I must take whole manifold to get to the flaps... and I should do the both sides.

how do You fix the flaps? only with a plastic zip? As I guess You tie the part wich lifts the flaps up and down, so it didn't has a lot of space and stick well... am I right?
 
#33 ·
Yes and you dont need to take it all apart,you just tie a leaver that moves the flaps you will see it,it conects the electric engine with the flaps. You just tie that lever so it couldnt fall down so much but make sure you dont do it so tight and leave it space to work. Do what i told you,look at those machanism while someone else starts the car. You will notice that one of them is stucked,feel free to push it up or down with a finger and it will start working,and you will see how little help it needs to start working every time you start a car. What is your mileage?
 
#35 ·
Yes,that is a vise thing to do considering your big mileage... First thing you can do is to take off the metal pipe that goes on the EGR and see how dirty it is...if it isnt to much dirt you can spray some cleaner in it and blow it with a preassure air
 
Discussion starter · #36 ·
Hi All,
Looks like an ongoing saga with my A5. After cleaning out the lower inlet manifolds (didn't get chance to do the write up about it yet) the EML is on again. Same code as always EGR insufficient flow. I've taken off the egr valve and it had a light coating of carbon but i was actually surprised at how 'clean' it looked. Stuck my fingers into the cooler and felt past the bypass butterfly valve; again lightly coated but certainly not blocked.

So cleaned and replaced the valve and within 100miles, code thrown again (took upwards of 3k miles since manifold clean to come back on).

So... I don't want to start renewing parts unless i have to. Has anyone had similar issues? what was the remedy? I'm fine with replacing the egr valve if it's that, but don't so much fancy doing the EGR cooler, since the dpf filter and all sorts of other things need dismantling...

be great to hear any similar experiences from you guys
cheers
 
Discussion starter · #37 ·
was looking at the advanced values in vcds today and found this
09:36:12
644.2 mg/stroke Actual air mass 002
20.79 % Air conditioner fan activation 003
18.68 % EGR valve activation 017
81.54 % EGR valve feedback 018
-4.05 % EGR valve output stage 019
11.79 % Throttle valve feedback 070
12.38 % Throttle valve activation 071
15.27 % Throttle valve output stage 072
63.88 % Intake manifold flap activation 081

looks like the EGR valve feedback is out of step with the activation. I presume they are supposed to be a similar value, within a defined tolerance?
 
#38 · (Edited)
Hi, I need some help guys.

I keep getting these fault codes;

2 Faults Found:
4807 - EGR System: Insufficient Flow
P0401 00 [096] - Short to Ground


5215 - Fuel Rail/System Pressure: Too Low
P0087 00 [032] - Cannot Be Tested at this Time

Car has done 100k miles/160k km, and I'm thinking it is EGR valve that need to be cleaned. What do you think?

Engine bay looks like a rats nest and I'm not really sure where to look fot the EGR valve :)
I hope someone wiser can show me, here is the pic of engine:

 
Discussion starter · #39 ·
Hi all,
just thought i'd update where i got to with my MIL light issue... last weekend i bit the bullet and fitted a new EGR cooler. took a long time but lights off so far (though only covered 100miles since doing it). Feels a little smoother at idle and lower down in rev range so hope it's cured it for good. Really shocked that a 4 yr old car with 63k miles needs such a job doing on it; EGR's seem very flaky. Certainly not the kind of quality I expect from Audi....

Anyway, i have a spare EGR valve brand new and unfitted to sell if anyone needs one. It'll fit the CCWA engine.
 
#40 ·
I recently had this EGR fault code with the engine malfunction lamp on:

Address 01: Engine Labels: 059-907-401-CAP.clb
Control Module Part Number: 8R0 907 401 J HW: 8K1 907 401 A
Component and/or Version: 3.0TDI EDC17 H02 0008
Software Coding: 011C002C240F0020
Work Shop Code: WSC 01000 264 59545
ASAM Dataset: EV_ECM30TDI0118R0907401J 001008 (AU48)
VCID: 3973DF35B842B31
1 Fault Found:

4807 - EGR System
P0401 00 [104] - Insufficient Flow
Intermittent - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 27
Mileage: 60157 km
Date: 2012.08.15

I have to say that my ECU was flashed last year by my AUDI dealer under warranty as per some official TSB-Campaign so they have replaced the firmware of the ECU just to eliminate this kind of error that was sporadically present but it was (not confirmed) :

4807 - EGR System
P0401 00 [096] - Insufficient Flow
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 34
Mileage: 56927 km
Date: 2012.06.24

being not confirmed. no lamps were on in my dashboard so it was ignored by me also because the engine performace was and it is always very strong without loss of power or other problems (I love this engine).
After 1 day with the lamp on I tried to push hard on the accelerator and after some kilometers of a very hard performance on my preferred mountain road..... miracle!! the Engine lamp is gone.
It is evident that I have some problems on the EGR System but what to do? or better: is it an EGR valve problem or an EGR cooler issue?
My cab is a january 2010 with 62.000 KM so my warranty period has expired last january. I asked to the dealership a repair under warranty because they knew this problem since the beginning but they asked me about 1000 EURO for the EGR VALVE and the EGR cooler substitution because the car exceeded 50.000 KM

What to do?

Thanks in advance for any help.
 
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