a6 3.0 tdi po401 insufficent flow

[jimmybond1]

hi, new to the forum I think lol.
sure I was jimmybond before but computer says no.

ok I decided to get my car remapped.
the guy who did the work said I have a egr problem as we speak.
months ago the engine light did come on. it was a egr code but cant remember what.
anyway, was deleted been no agro ever since.

so the car got remapped, wanted a bit more balls and better mpg.
after all the software came through the guy said im gonna do a egr delete for you.

ive never had a remapped car before.

I thought to myself oh the pains I get off the late ford rangers when I block there egr off, the same sort of problems im getting with my car:aargh4:


then I thought oh well this guy must know what hes doing so said nothing.

now at this point all good, 2 days later engine light on.
po401
rang the guy up he said egr needs a clean as not sealing.
I busted my balls getting this egr out.
the engine has not been touched in anyway except servicing.
egr was not to bad but after blowing up hole yes I can see it is not sealed as its hissing.
I blocked the pipe with a steel plate.
each morning now the code of po401 comes back saying insufficient flow.

this is exactly what i get when i block of later cars egrs etc then i start by drilling a 7mm hole and working my way up until no engine light on.
i assumed as he said egr was deleted that the ecu would not flag up a fault code.

so guys is there anybody on here that have any knowledge on a egr delete.
do you think the software in ecu is wrong or is the car at fault.
i had no light on before but the guy in all fairness did show me on his machine that it showing the egr problem which i thought was strange as no engine light on.
the code could not be deleted btw.
any suggestions welcome.
im basically ******* in the wind here myself.
tar lloyd

[rowdy-999]

I can't help with the problem, but it sure made my head hurt reading your post.

[jimmybond1]

I was on my mobile.
This site not mobile friendly.
Even a tablet its hard delete te
I cant hit the new reply button either.
Any help be great.
I keep getting p0401 code up.
I had car remapped monday and guy said ive got a egr problem so did a egr delete aswell.
Now im faced with engine light on.
Wanted to know is this a carbon build up problem?

[jimmybond1]

ok got the laptop out.
much better.
ok how do I put this in the section I need it in.
sorry really struggling here.

I had the car remapped Monday guy was using kess, went for max power.
the guy in all fairness did say you have a egr problem.
2 or 3 months ago the engine light did come on.
code was for egr, I cant remember what it was, code was deleted and not seen light since so I assumed all good.
car went to get remap done Monday, just wanted 40 mpg really, normally 35 to 37 mpg.
ok as I had the fault code of the egr in ecu but no light on, the guy done a egr delete.
my car is 55 plate audi Quattro 3.0tdi auto with a bkm engine 100,000 miles.
car has never been no agro, only had servicing.

I have never had a ecu remapped only cars where the ecu has been reflashed.

ive played about with the car and ended up just sticking a piece of metal across the egr to blank it but this made my problem worse.
i thought as deleted egr i could block off.
i know 1st thing in the morning the light on in very short distance.
it would last 2 days with no steel plate in.
so i assume the egr still works to help bring up engine temp when engine cold.

is this just a case that there is a large carbon build in manifolds etc as car has never had a spanner to it except 1 wheel bearing and reverse sensors.
the fault code is always the same p0401 low gas flow or something along them lines.
any ideas anyone?

[zollaf]

not all faults put the light on. but, simple thing is, you have an egr fault. not all cars will allow the egr to be mapped out. i think you need a new egr valve.

[MarkTM]

My insufficient flow message was from the nostrils blocked in the cast metal pipe leading to the inlet manifold, but as my EGR is operational I would get this.

Cleaning process is highlighted here:

Audi A6 2.7 & 3.0 TDi EGR & Intake system cleaning info please... (http://www.vwaudiforum.co.uk/forum/showthread.php/141451-Audi-A6-2-7-amp-3-0-TDi-EGR-amp-Intake-system-cleaning-info-please?highlight=cleaning+inlet+manifold).

You don't need to be mechanically minded to do most of it...I'm not and could manage, just follow the cleaning process including throttle body.

As to the blow test, I assume it shouldn't do this so perhaps a bad joint or split pipe?

[jimmybond1]

thanks guys.
yes im thinking along the lines it needs the egr cooler cleaned and deffo a egr valve.
I blew straight on the valve by the way.
it deffo leaking through so a rough seat im guessing.
ok today after more peeing about ive checked the operation of the egr.
cold yes it works, this is to help it warm up.
so I removed my steel plate.
the light stays out but I know it wont last for long.
but how ever after a journey yes the code is back but no light so im assuming its deffo a fault on the car, the remap shows it up more.
possibly due to higher boost.
ive been looking through the net for a egr valve but with no joy.
its clear now I gotta have egr valve as it is needed for warm up period.
im just gonna fit new valve then see what happens.

I looked in live data at data block 3
im sure this is my egr.
I have
rpm 790
mgh 540 550
mgh 185
duty cycle 0%
so to me the volume of air by air flow meter seems to low for a 6 cylinder.
im hoping this is due to egr leaking.
time will tell.
but any info guys or ideas they be well welcomed.
I never get agro with this car ever.