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


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....

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.