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Persistent P0401 EGR insufficient flow after EGR replacement

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61K views 79 replies 12 participants last post by  sbones  
#1 ·
Hi folks, I had my EGR replaced about six months ago to resolve an insufficient flow issue, and everything was fine. Now, though, the issue is back to haunt me, if I clear it, it returns in a few days.

I use quality fuels, so no problem there. Will one of those carbon clean gas services possibly help? Or do I need a new EGR cooler, or to rip the whole thing apart and clean up all the carbon? Or is anyone aware of anything else that throws this error?
 
#67 ·
Quick up date if anyone else having the p0401 restricted flow, did this like 6weeks ago, & fault hasn't come back at all.
Not only that just looked on my dpf app for the 1st time since.
Used to regen at 96% after about every 250 - 300 miles, now it looks like it's already been 362 miles since & it's only. 20% full.
So a lot more soot & gases are been burnt more efficient.
Image


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#68 ·
That does seem right surely??? Mine never regens below 20% or 4g! Sorcery!
Definitely need to find time to clean that bastard up

Edit: actually that worries me, your soot mass measured is 15g, but calc is 4. Usually the calc is way higher than measured, like 10x more.
 
#71 · (Edited)
DPF, for 3.0TDI is important oil ash, grams are not important at all.

Max oil ash is 370 ml=0,37 l, so if You have 470=0,47 l, DPF must be changed or cleaned by cleaner not by burning at car.
It is oil ash which is not cleaned by usuall burning process.

I did look at our Q5 3.0TDI with 123000km, Oil ash is 0,16 l.
 
#72 ·
It's not done a regen at 20% that's just when I screen grabbed, it usually regens at around 96% progress bar at top, then after the soot levels go right down.
I'm not sure what the normal level of soot & ash are.
Didn't clean the egr, just the little pipe where joined the inlet was blocked

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#74 ·
Take the entire aluminium part of the air intake off, I'd link to the thread that explains but don't have it to hand. Not a huge job, pretty simple from the pictures, though I haven't done it yet.
 
#77 ·
I reckon I fixed this at last by unclogging the intake manifold (was really really funked up around the EGR connection) followed by an EGR regen!