EGR? valve?

**JamieG** · 23-09-2016,04:55 PM

Hi all

I've a problem with my 2007 2.0TDI Quattro 170, heres whats happening, when towing I get SEL lights up when pulling away hard in 4th gear, up hills also when requesting more power.

Also getting these errors without towing now, going up a hill from work I can be 5th gear at 55mph around 2000rpm, when I request more power medium not hard power I get SEL and limp mode. I've checked over the car for VAC leaks and cant see anything. I've also changed the DPF sensor as mine had gone "G450" , the old one wasn't recording the % clogged on the DPF probably for a couple of years as the car hasn't complained about needed a regen, most of my driving is in and around town. An adaptation was run on the new sensor prior to switching on the engine.

So original log from towing recently before changing the DPF sensor G450

Sunday,14,August,2016,11:10:27:19797
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 16.8.0.0 (x64)
Data version: 20160731 DS254
www.Ross-Tech.com

VIN: WAUZZZ8E38A014205 License Plate:

Chassis Type: 8E (8E - Audi A4/S4/RS4 B6/B7 (2001 > 2008))
Scan: 01 02 03 08 09 0F 11 15 16 17 18 25 36 37 45 46 55 56 57 65
67 69 75 76 77

VIN: WAUZZZ8E38A014205 Mileage: 111150km-69065miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-018-BRD.clb
Part No SW: 03G 906 018 AQ HW: 03G 906 018 AQ
Component: R4 2.0l PPD1.3 G 9971
Revision: --H43--- Serial number: XXXXXXXXXXXXXX
Coding: 0000172
Shop #: WSC 00502 210 91535
VCID: 74EC23F717F67AE2B7-8020
1 Fault Found:
000665 - Boost Pressure Regulation
P0299 - 006 - Control Range Not Reached - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100001
Fault Priority: 5
Fault Frequency: 6
Reset counter: 40
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 2400 /min
Torque: 280.0 Nm
Speed: 56.0 km/h
79.95 %
Voltage: 13.56 V
Pressure: 2449.5 mbar
Pressure: 1746.6 mbar
Readiness: N/A

______________________________________
Also prior to the G450 change

Wednesday,24,August,2016,20:53:14:19797
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 16.8.0.3 (x64)
Data version: 20160803 DS255
www.Ross-Tech.com

VIN: WAUZZZ8E38A014205 License Plate:

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------

Chassis Type: 8E (8E - Audi A4/S4/RS4 B6/B7 (2001 > 2008))
Scan: 01 02 03 08 09 0F 11 15 16 17 18 25 36 37 45 46 55 56 57 65
67 69 75 76 77

VIN: WAUZZZ8E38A014205
-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-018-BRD.clb
Part No SW: 03G 906 018 AQ HW: 03G 906 018 AQ
Component: R4 2.0l PPD1.3 G 9971
Revision: --H43--- Serial number: XXXXXXXXXXXXXX
Coding: 0000172
Shop #: WSC 00502 210 91535
VCID: 74EC23F717F67AE2B4-8020
1 Fault Found:
001137 - Exhaust Pressure Sensor 1 (G450)
P0471 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00010001
Fault Priority: 1
Fault Frequency: 1
Reset counter: 40
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 0 /min
Torque: 136.0 Nm
Speed: 5.0 km/h
Pressure: 106.5 mbar
Text: -105 mbar
Text: 252 C
Temperature: 19.5°C
Readiness: N/A

_______________________________________

Since changing the G450 I've had this show up

Tuesday,27,December,2016,20:52:56:19797
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 16.8.0.3
Data version: 20160803 DS255
Ross-Tech: Home

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------

Address 01: Engine Labels: 03G-906-018-BRD.clb
Control Module Part Number: 03G 906 018 AQ HW: 03G 906 018 AQ
Component and/or Version: R4 2.0l PPD1.3 G 9971
Software Coding: 0000172
Work Shop Code: WSC 00502 210 91535
VCID: 74EC23F714F67AE2B4-50E6
2 Faults Found:
012592 - EGR System
P3130 - 006 - Regulation Range Exceeded - Intermittent
000665 - Boost Pressure Regulation
P0299 - 006 - Control Range Not Reached
Readiness: N/A

__________________________________________________ _______________________

When requesting more power up the large hill from work I've now got these popping up.

Thursday,22,September,2016,16:40:44:19797
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 16.8.1.3
Data version: 20160902 DS256
Ross-Tech: Home

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------

Address 01: Engine Labels: 03G-906-018-BRD.clb
Control Module Part Number: 03G 906 018 AQ HW: 03G 906 018 AQ
Component and/or Version: R4 2.0l PPD1.3 G 9971
Software Coding: 0000172
Work Shop Code: WSC 00502 210 91535
VCID: 74EC23F717F67AE2BA-8020
4 Faults Found:
012592 - EGR System
P3130 - 006 - Regulation Range Exceeded - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 1
Reset counter: 14
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 864 /min
Torque: 32.0 Nm
Speed: 0.0 km/h
21.45 %
Load: 21.6 %
Lambda: 0.0 %
Battery Volts: 1.0 V
000665 - Boost Pressure Regulation
P0299 - 006 - Control Range Not Reached
Freeze Frame:
Fault Status: 11000001
Fault Priority: 5
Fault Frequency: 2
Reset counter: 40
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 2144 /min
Torque: 264.0 Nm
Speed: 97.0 km/h
68.64 %
Voltage: 14.01 V
Pressure: 2151.3 mbar
Pressure: 1746.6 mbar
005187 - Potentiometer for EGR (G212)
P1443 - 007 - Signal too Low - Intermittent
Freeze Frame:
Fault Status: 00000010
Fault Priority: 1
Fault Frequency: 1
Reset counter: 39
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
0.00 %
Battery Volts: 1.0 V
Mass Air / Rev.: 0.0 mg/str
Mass Air / Rev.: 0.0 mg/str
012593 - EGR System
P3131 - 006 - Regulation Range not Reached - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 1
Reset counter: 39
Mileage: 0 km
Time Indication: 0
Freeze Frame:
RPM: 800 /min
Torque: 48.0 Nm
Speed: 0.0 km/h
0.00 %
Load: 0.0 %
Lambda: 99.2 %
Battery Volts: 1.0 V

Readiness: N/A

Is this pointing to the EGR valve, I believe they are electronic on my BRD engine.

I have VCDS and can do live testing so if more probing is required please let me know so I can isolate this little bugg3r.

Any help greatly appreciated.

Thanks

**nevo** · 26-09-2016,09:58 AM

The egr is indeed electric,probably a good idea to take it off and give it a clean also the intake manifold will be gunked up,pay attention to the oval flap on the egr it has a habit of coming adrift also shine a light behind it see if it seats without passing. sounds like its not regening too,sweep your finger round the exhaust pipe exits see if there's any oil.While you're there check the operation of the vacuum operated manifold flap,see if it holds a vac.

**JamieG** · 26-09-2016,11:14 AM

With this issue the car runs fine at idle no issues anywhere apart from this.

I've also checked measuring blocks 84, this shows lamda at idle and running, at idle the ECU is dumping 22% of fuel in, when no idle its at 0% - read this kinda suggests a vac leak somewhere. - round and round.....

**JamieG** · 18-10-2016,03:23 PM

Thanks again for the information - I've now removed the intake manifold and cleaned through, as with the EGR and intake flap, I've replaced all gaskets when putting back - still getting this issue, however not so often anymore, it was appearing between 2400 up to 4500 and this is still the case. I'm also at times getting correct boost, I've logged a few requested against actual and previously the actual was around 1000 below the requested, where as now I'm getting the actual up with the requested, but this error is still popping up now and again. Had it in 6th gear around 1500 requested more power and it SEL'ed before 2000rpm.

**JamieG** · 18-10-2016,06:14 PM

I've run a measuring block against 011 - this has ruled out the EGR at fault as the request and actual are bang on.

Just driven home the car was feeling perfect, giving loads of power up a hill that I use to test, I've graphed it below, then up the next hill SEL light on and underboost. Anyone offer and help?

Perfect graph

A1.jpg

Under Boost and SEL on

Underboost.jpg

**JamieG** · 19-10-2016,03:29 PM

Is there a way with VCDS to check fuel flow? - plus the above too

**nevo** · 20-10-2016,12:16 PM

Sounds like you've got a vac leak or maybe, the tandem pump itself,also on the intake manifold there's a actuator near the cambelt end check that is holding a vac.

**JamieG** · 20-10-2016,12:30 PM

HI

I've not found a vac leak yet - can't hear hissing at all- the car will rev to red line when it doesn't error "I'm finding it harder and harder to get it to error now too", I've got a mityvac on the way. The changes I've made to get the graph of boost where it is, I've changed the AUDI A4 B8 / A5 8T 2.0 TDI EGR / TURBO VACUUM SOLENOID VALVE 1K0906283A 08-15, prior to doing this my requested and actual were about 1000 out, I've checked the intake manifold actuator, this holds a vacuum, done by mouth, probably may need more PSI rather than a good suck.... - The plug down on the EGR/Turbo solenoid was extremely tight so I've given a little more slack through, need to get the wire cover off to check condition of that wire as this all improved after messing in that area.

Now here's what I've found the other day, It boosted perfectly and has loads of power now each day, it's driving like a different car, but the other day I was stuck in traffic going around 5mph for 10 minutes, the failed graph above is straight after that, so it looks like when something is very hot it's not quite working right.

What is the tandem pump and what does it do please? any ideas where this is on a BRD B7 and how I can test?

**nevo** · 20-10-2016,03:37 PM

Have a read of this. B7 Tdi 170 Avant, low boost issues - Page 3

**JamieG** · 20-10-2016,05:20 PM

Yup I've read that one, fact is I've read so so so much it's unreal about this issue now. Although people say vac leak a lot of what I've seen hasn't been vac leak

I need to investigate the wiring at the next decent light opportunity so I can have a good look as messing in that area has given me 170bph back that goes back to a 1.4 now and again, could be vibration dislodging the wires etc, gonne try tonight and get a file in the female connector of the actuator control module that I replaced.