[Disca]

Digging up an old thread but the project managers A5 3.0TDI has apparently been diagnosed with required a replacement of the system surrounding the EGR.

Audi said it should cost 1400~ but will do it for 600+VAT so still quite high.

Anything worth mentioning to him? I sadly don't know what the error codes it was throwing are

 

[Oscartango]

Just do it and get it over with... I tried going cheaper by replacing only the egr valve and have the cooler cleaned, no result... Software update : no result... Cable loom replacement : no result... In the end got cooler + egr valve exchanged and the light and the codes disappeared. Cost me as much as when I would have had it done by the way Audi dealer. And it took months in total.

 

[A5driver]

Quick question for those who have taken out their EGR valve: is it just 3 torx screws that need to be taken out?

I haven't had the MIL on or anything, but noticed the dreaded "egr insufficient flow" error was there (says 'unconfirmed') when I did a scan the other day ... also had it once a year or 3 ago, just cleared it and it didn't come back until recently.
I just want to have a peek at the valve to see if it needs to be cleaned after 70K km. I've losened up the 3 trox screws a bit, but the valve doesn't budge at all. Is it attached with something else? By looking at the picture of the valve, I also only see 3 holes for the torx screws.
Can anyone who has taken it out confirm its just 3 screws and then maybe force to jank it out?

Don't get why dealers charge so much to replace EGR valves, seems easy to access and a new pierburg EGR valve is just €145 (at ebay)

 

[bigkaban]

Ccwa egr

Hi MONGS i have q5 with ccwa engine and i have fault.. p0401 insufficient flow.. only solution is replace cooler egr and valve egr?? im cleaning and buy used cooler and from 2012 year... my car is 2008... no result.. thanks for recipient and sorry for my english.. im from Poland... greetings.

 

[jakzon]

Hi MONGS i have q5 with ccwa engine and i have fault.. p0401 insufficient flow.. only solution is replace cooler egr and valve egr?? im cleaning and buy used cooler and from 2012 year... my car is 2008... no result.. thanks for recipient and sorry for my english.. im from Poland... greetings.

you could try replacing the solenoid mentioned in previous posts.
theres a guy in poland selling them for 18 euro on ebay.

 

[bigkaban]

im buy solenoid for... 2.5 Euro... replace in free time

 

[C99]

No, it really is "EGR cooler burning/cleaning", I use it every Year on our Q5 and still no problem after 60 000 km.

Still no EGR problem after 90 000 km.

 

[sbones]

Is this EGR related? Had my engine light come on a few time in last week's was waiting to see if carbon clean would clear it up but still came back on I clear fault but comes back in around 50/60 miles

 

[jakzon]

Still no EGR problem after 90 000 km.

Hi mate,

can you enlighten us on how to perform the EGR regen?

thanks.

 

[bigkaban]

One day after replacement solenoid is good- no fault. Today check again and post result.
Next day no fault- solenoid solved problem [emoji6]

Wysłane z sixeSa

 

[sbones]

Called in at dealer to ask about EGR they wanted £60 to plug in to make sure what it definitely is that, but asked if iv done a regeneration' dpf regen lights never been on & they said it can clean the EGR also?? been driving steady really since had it & been getting good mpg (even better since carbon cleaned) 41 - 44pmg.
Just driven to Manchester & back over the Peak District, nice driving road & without thrashing stayed in 4th gear about 3k revs. Touch wood light never came on at all! There & back. Tank of Vpower too

 

[bigkaban]

Slow drive= fault. Speed drive = no fault.


Wysłane z sixeSa

 

[sbones]

Same speed + high revs + regeneration =

 

[sbones]

This page always comes up 1st if you Google Audi egr Insufficient Flow
So thought I'd share what I did
Had the Insufficient Flow code on & off for last year.
Knew egr valve was working as can see the open closed % on torque & vag dfp app.
Took the inlet off, was black inside but nothing too bad since has 200k on it.
But where the egr outlet pipe meets the intake it was coked up there.
Chipped away what I could & soaked in oven cleaner, so all nice & clean.
No fault code or lights any more.
So hopefully sorted it, without removing too much or egr itself.

Sent from my SM-N950F using Tapatalk

 

[Eamonn]

This page always comes up 1st if you Google Audi egr Insufficient Flow
So thought I'd share what I did
Had the Insufficient Flow code on & off for last year.
Knew egr valve was working as can see the open closed % on torque & vag dfp app.
Took the inlet off, was black inside but nothing too bad since has 200k on it.
But where the egr outlet pipe meets the intake it was coked up there.
Chipped away what I could & soaked in oven cleaner, so all nice & clean.
No fault code or lights any more.
So hopefully sorted it, without removing too much or egr itself.

Sent from my SM-N950F using Tapatalk

Any tips on how to get those bits off to clean them? I've had this fault come and go for years. New egr, cooler, neither helped.

 

[sbones]

Few torx head bolts for intake (red)

17mm&19mm nuts (blue) for diesel rails small one comes off large just loosen.

(green) egr flexi pipe to inlet

Jubilee clip for intercooler pipe

Bit of a jiggle & intake pipe comes away, then get to other end of egr flexi.
I soaked all insides with Mr Muscle oven clean for about 1 hour, wiped clean what I could, then picked away with stubborn carbon from small holes. Soft wire brush wheel on drill is good too, dried out with hot air gun & wiped out with solvent.
Been 3 weeks & fault code not come back, & sure it feels smoother on pick up

Sent from my SM-N950F using Tapatalk

 

[Eamonn]

Few torx head bolts for intake (red)

17mm&19mm nuts (blue) for diesel rails small one comes off large just loosen.

(green) egr flexi pipe to inlet

Jubilee clip for intercooler pipe

Bit of a jiggle & intake pipe comes away, then get to other end of egr flexi.
I soaked all insides with Mr Muscle oven clean for about 1 hour, wiped clean what I could, then picked away with stubborn carbon from small holes. Soft wire brush wheel on drill is good too, dried out with hot air gun & wiped out with solvent.
Been 3 weeks & fault code not come back, & sure it feels smoother on pick up

Sent from my SM-N950F using Tapatalk

Did you replace any gaskets/seals during the process? How long you reckon start to finish? Mines started to come on almost permanently now, and I know for a fact my EGR valve and cooler is fine.

 

[sbones]

Did you replace any gaskets/seals during the process? How long you reckon start to finish? Mines started to come on almost permanently now, and I know for a fact my EGR valve and cooler is fine.

No gaskets, on inlet these a thick rubber seal, I'd say taking time half hour to remove, spent 2hours soaking & cleaning, & half hour to refit. Been 2 month now & no codes came back [emoji4]

Sent from my SM-N950F using Tapatalk

 

[sbones]

Rubber seals, wiped them clean too

Sent from my SM-N950F using Tapatalk

 

[atana5ov]

Hi everyone.

My vehicle is a 2010 A5 Sportback 3.0 TDI (CCWA) 239 bhp mapped to 295ish bhp by a custom tuner here in Bulgaria. EGR, DPF, swirl flaps all there and working, to the best of my knowledge.

Will give you a brief summary of my issues, really hoping someone can point me in the right direction.

4807 - EGR System | P0401 00 [096] - Insufficient Flow | 05.04.2018 - cleaned error
4807 - EGR System | P0401 00 [096] - Insufficient Flow | 09.03.2019 - cleaned error
4794 - Mass Air Flow Sensor (G70) | P0101 00 [096] - Implausible Signal | 24.04.2019 - cleaned error
4807 - EGR System | P0401 00 [096] - Insufficient Flow | 25.04.2019 (my birthday, unfortunately) - cleaned error
4807 - EGR System | P0401 00 [032] - Insufficient Flow | 02.05.2019 - cleaned error
4794 - Mass Air Flow Sensor (G70) | P0101 00 [237] - Implausible Signal | 11.05.2019 - MIL - cleaned error - MIL disappeared

These 3x EGR errors and 2x MAF errors in the past 2 months make me think that this issue needs addressing and cannot be delayed any longer. In must be noted that the car after the remap used to give a mixed (50% urban -50% highway) fuel consumption of 9.2-9.5 l/100km, in the past 3-4 months it went up to 10.6 l/100km mixed. Just wanted to mention that as it might be related.

Having read this thread and other similar ones, I am under the impression that it is due to one of the reasons below:

1. EGR valve might be clogged and needs cleaning. As the clogged EGR valve stays open longer than intended, that messes up with the MAF sensor (hence the implausible signal). The wrong ratio of fresh air to exhaust gases messes up the engine productivity due to higher temperature of the air (exhaust gases) and the lack of oxygen (again, exhaust gases), leading to higher fuel consumption.

2. EGR cooler is faulty and needs changing, as discussed on pages 2 and 3 of this thread.

Car has 128,000km on the clock, to the best of my knowledge, not a first owner you see. Oil and filters (air, diesel, oil and pollen) changed every 10,000-12,000km. Car is a daily, driven enthusiastically but not over agressively. Always run on Shell V-Power Diesel.

I assume that by not keeping this thread alive, most of you have either moved on from the CCWA A5 or have resolved the issue. In any case, if someone can point me in the direction of how to definitively solve the Insufficient Flow mystery, please drop a line or two.

Car is scheduled with an indie garage next week for cleaning of the EGR valve and the MAF sensor, but my suspicion is that that alone will not resolve the matter.

Looking forward to any know-how and comments.

Thanks for reading!