vw golf mk6 1.6 tdi cayc engine P0402 FAULT CODE

[jumpjetguy]

Hi, new guy here with a question to fellow members.Just had the dreaded flashing glow plug appear on the drive home. Vcds connected and fault code shown as P0402
EGR excessive flow.Has anyone experienced this on their VW.AUDI/SEAT/Skoda vehicle?.If so could it be resolved without trip to main agents,i have seen this on YouTube please see link Fault code P046C. ( VW golf 1.6 TDI Mk 6. 2011) EGR Valve 03L-131-512-AT - YouTube. Could anyone who has experienced the same fault share info on best way forward to resolve this issue
best regards to all

[jumpjetguy]

Hi to all, thought i would post an update ref my VCDS readings on the P0402 fault code. VW GOLF MK6 1.6 TDI CAYC 2009.When first start in the morning engine cold,i can hear the engine hunting before settling to normal 800 rpm idle.This has only occurred since this fault code appeared this.My initial thoughts are this is the air intake flaps fluctuating altering amount of airflow.Never use to hear this symptom prior to fault. Seems to disappear after approx 30 seconds when engine rps stabilizes at approx 800 rpm.On first drive no flashing glow plug light,however after approx 4-5 miles flashing glow plug appears on dash.From what i have seen on internet this points to stuck /sticking EGR valve in the EGR cooler assembly.Any help or thoughts guys would be most welcome.Looks like a difficult job to remove and de carbon this EGR valve.Especially as results are uncertain as to long term fix.Someone must have experienced this same problem i an sure.It appears all CAY-CAYC Engine owners are due to suffer from this,just a matter of time like a ticking time bomb



Chassis Type: 1K0
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 56


VIN: WVWZZZ1KZAP083446


01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine (J623-CAYC) Labels: 03L-906-023-CAY.clb
Part No SW: 03L 906 023 B HW: 03L 906 023 A
Component: 1,6l R4 CR td H23 8831
Revision: --H23--- Serial number: 00000000000000
Coding: 00114014030500080000
Shop #: WSC 00028 028 00024
ASAM Dataset: EV_ECM16TDI02103L906023B 003007
ROD: EV_ECM16TDI02103L906023B_VW36.rod
VCID: 254BEF4D24FA271


1 Fault Found:
7336 - EGR System
P0402 00 [101] - Excessive Flow
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 5130 km
Date: 2082.14.06
Time: 16:25:39


Readiness: 0000 0000


-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104) Labels: 1K0-907-379-60EC1F.clb
Part No SW: 1K0 907 379 AH HW: 1K0 907 379 AH
Component: ESP MK60EC1 H30 0107
Revision: 00H30001
Coding: 133B200D092A00FDC80F04E8901F0080300000
Shop #: WSC 00028 028 00001
VCID: 78F5F639CBC86A9


No fault code found.


-------------------------------------------------------------------------------
Address 08: Auto HVAC (J301) Labels: 3C8-907-336.clb
Part No SW: 3C8 907 336 AB HW: 3C8 907 336 AB
Component: Climatic H14 0305
Revision: 00009001
Coding: 0000000002
Shop #: WSC 00028 028 00024
ASAM Dataset: EV_Climatic A01005
ROD: EV_Climatic_VW36.rod
VCID: 6DDBD76DBC8ADF1


No fault code found.


-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519) Labels: 1K0-937-08x-09.clb
Part No SW: 1K0 937 084 B HW: 1K0 937 084 B
Component: BCM PQ35 B 103 0573
Revision: 00103 AF
Coding: 40180A3A9025180044000080300000E443010088534D816064 8000200000
Shop #: WSC 00028 028 00001
VCID: 2D5B176D740A1F1


Subsystem 1 - Part No: 1K2 955 119 F Labels: 1KX-955-119.CLB
Component: Wischer 15100 21 0512
Coding: 009795


1 Fault Found:
00061 - Footwell Lights
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 5
Fault Frequency: 5
Reset counter: 79
Mileage: 58967 km
Time Indication: 0
Date: 2018.14.06
Time: 16:19:06


Freeze Frame:
Term 15 Off
Voltage: 12.00 V
OFF
ON
Term 50 Off
OFF
OFF




-------------------------------------------------------------------------------
Address 15: Airbags (J234) Labels: 5K0-959-655.clb
Part No SW: 5K0 959 655 HW: 5K0 959 655
Component: AirbagVW10 036 0604
Serial number: 003C2D0HC0GW
Coding: 00003230
Shop #: WSC 01383 790 00056
ASAM Dataset: EV_AirbaVW10SMEVW360 A01009
ROD: EV_AirbaVW10SMEVW360_VW36.rod
VCID: F7F775054ED6E51


Crash sensor for side airbag; driver side:
Subsystem 1 - Part No SW: 5K0 959 354 HW: 5K0 959 354
Component: S.Sens.Fahr.V H01 ----
Serial number: 792C504AZZZZZZZZZZZZ


Crash sensor for side airbag; passenger side:
Subsystem 2 - Part No SW: 5K0 959 354 HW: 5K0 959 354
Component: S.Sens.Beif.V H01 ----
Serial number: 6553504AZZZZZZZZZZZZ


Crash sensor for side airbag; rear driver side:
Component: S.Sens.Fahr.H --- ----
Serial number: 300F3F6EZZZZZZZZZZZZ


Crash sensor for side airbag; rear passenger side:
Component: S.Sens.Beif.H --- ----
Serial number: 3429400DZZZZZZZZZZZZ


No fault code found.


-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY9.lbl
Part No SW: 1K0 953 549 CQ HW: 1K0 953 549 CQ
Component: J0527 053 0111
Coding: 0000004
Shop #: WSC 00028 028 00001
VCID: 830F11D5C20EB91


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments (J285) Labels: 5K0-920-xxx-17.clb
Part No SW: 5K0 920 960 N HW: 5K0 920 960 N
Component: KOMBI H04 0308
Serial number: 00000000000000
Coding: 470B00
Shop #: WSC 00028 028 00024
ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04052
ROD: EV_Kombi_UDS_VDD_RM09_VW36.rod
VCID: 387536398348AA9


No fault code found.


-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 1K0-907-530.lbl
Part No SW: 1K0 907 530 AD HW: 1K0 907 951
Component: J533 Gateway H07 0111
Revision: H07 01 Serial number: 211009F1000901
Coding: E9801F06000202000001
Shop #: WSC 00028 028 00001
VCID: 69D3A37D4062C31


No fault code found.


-------------------------------------------------------------------------------
Address 25: Immobilizer (J334) Labels: 5K0-920-xxx-25.clb
Part No SW: 5K0 953 234 HW: 5K0 953 234
Component: IMMO H04 0308
Serial number:
Coding: 000000
Shop #: WSC 00000 000 00000
ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03005
ROD: EV_Immo_UDS_VDD_RM09_VW36.rod
VCID: EAD15C710D64489


No fault code found.


-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN3.lbl
Part No SW: 5K0 959 701 D HW: 5K0 959 701 D
Component: Tuer-SG 009 2122
Coding: 0000628
Shop #: WSC 00028 028 00001
VCID: 336F0115522E491


No fault code found.


-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb
Part No: 1K0 909 144 J
Component: EPS_ZFLS Kl. 69 3001
Revision: 00H17000
Shop #: WSC 00028 028 00001
VCID: 31630B1DA8327B1


No fault code found.


-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN3.lbl
Part No SW: 5K0 959 702 D HW: 5K0 959 702 D
Component: Tuer-SG 009 2122
Coding: 0000628
Shop #: WSC 00028 028 00001
VCID: 346D020957204E9


No fault code found.


-------------------------------------------------------------------------------
Address 56: Radio (J0503) Labels: 5M0-035-1xx-56.clb
Part No SW: 3C8 035 195 G HW: 3C8 035 195 G
Component: Radio RCD510 050 0207
Revision: 00000001 Serial number: VWZ1Z3M7089804
Coding: 01000400040005
Shop #: WSC 00028 028 00001
VCID: 2C5D1A694F10169


No fault code found.


End ------------

[Crasher]

Just fit a new valve, cleaning them doesn't work. I have tried an aftermarket unit as an experiment and OK so far after a few months but until I am happy I still prefer genuine because of the 2 year labour inclusive warranty. These units are such a sod to fit that it makes life simpler but then again I have not had a replacement fail yet and we have been doing a lot of these over the last three years. The worst one is the A1 and the Polo, there is so little space around the unit it takes twice as long as a Golf 6.

[jumpjetguy]

Hi Crasher, thank you for your kind reply to my question,i will take it that i am on the right track then with this assumption its the EGR flow valve causing this fault code P0402?
Have followed many of your answers and suggestions to other members problems,so i respect your knowledgeable/professional opinion.Am i correct in assuming this job will take approx 4-6 hours for a technician, at a garage with all the equipment car lift etc.Also is the cost likely to be approx £800 using as you suggest only genuine VW parts.I am now 59 years of age lifetime on spanners,but not automotive industry.Don't fancy prospect of trying this removal/refitting process laid on my back with car on axle stands.Possible maybe but bloody difficult even if this allows access room

[Crasher]

i will take it that i am on the right track then with this assumption its the EGR flow valve

Assumption is a dangerous thing, I say "always check" but it has got to the point that if I get anything with a CAYC engine come in with the MIL on, I almost don't bother to code read them now, it's nearly always the EGR valve. You need 03L 131 512 DQ plus you may need heat shield 03L 131 531 A if one isn't fitted and a pile of gaskets/fasteners.

[Keithuk]

VAG Error Code: 16786/07336/01026
EOBD II Error Code: P0402

Fault Location:
Exhaust Gas Recirculation (EGR) System - Excessive Flow Detected

Possible Cause:
Malfunction Indicator Lamp (MIL)(K83) active.
Reduced Exhaust Gas Recirculation (EGR).
Reduced Power Output/Engine running rough.
Increased Emissions.

Wiring/Connector(s).
Exhaust Gas Recirculation (EGR) Valve stuck open/leaking/faulty.
Exhaust Gas Recirculation (EGR) System leaking/faulty.

Possible Solutions:
Check/Replace all faulty Wiring/Connector(s).
Check/Clean Exhaust Gas Recirculation (EGR) System.
Read Measuring Value Blocks (MVB).
Check/Replace Exhaust Gas Recirculation (EGR) Valve.

When is the code detected?:
High Exhaust Gas Recirculation (EGR) flow control is detected.


VAG Error Code: 00061

Fault Location:
Footwell Lights - Electrical Fault in Circuit/Open Circuit/Short Circuit to Positive

Possible Cause:
Fuse(s).
Wiring/Connector(s).
Failed or incorrect bulb installed.

Possible Solutions:
Check/Replace Fuse(s).
Check/Replace all faulty Wiring/Connector(s).
Check correct bulbs are installed.


As taken from my new EOBD II Error Codes

[jumpjetguy]

Hi Kieth, thank you for your most kind input ref my current fault code problems.I am thinking that the solution to the foot well lights might be as you point out wrong bulb type fitted.I have retro fitted two front foot well lights,however these have LED type bulbs incorporated inside.The rest of my Golf mk6 1.6 tdi CAYC 2009 interior courtesy lights are all the old incandescent bulb type.So maybe a mismatch on the can bus system throwing this error code.No warning light on dash for this error however,only showing on VCDS scan.Other possibility is i used incorrect long coding for this retro upgrade.Please may i ask do you have any info on what the coding change should have been,for this mod on my three door Golf.However this is all small potatoes when viewed against my EGR fault code ref P0402 excessive EGR flow.Looking like i will have to bite the bitter pill and have this changed professionally at a reputable garage.Would be up for changing this myself even at 59 years of age,however experience tells me this is not the kind of job for a garage floor operation.With the car on axle stands not much access provided too low.Even when this has been replaced and fault cleared hopefully,the prospect of this reappearing in another 36,000 fills me with dread and not a little anger!!!
Such a blight on this VW engine model CAY - CAYC. Have read on internet forums VW owners are paying between £800-£1000 to have this item repaired by replacement.Wish i had known this when i bought the car new,would probably have opted for a petrol model.hindsight is a wonderful thing

[jumpjetguy]

Hi Crasher, thank you for the up date info and pic,mine is slightly different to your pic but not splitting hairs.My 2009 did not have the extra heat shield fitted that you mention,must have been brought in later. VW certainly never fitted it on their annual service for the first three year either the only update they did was a ECU software update. Would all be so easy if engine looked like this on a pallet,piece of cake to change bags of access.Oh well dream on i assume this is a pic of the later heat shield you mention not fitted on my 2009 model s-l1600 (100).jpgEGR cooler assy cayc.jpgEGR cooler assy 2.jpgegr heat shield new addition.JPGs-l1600 (41l).jpg

[Crasher]

If you don't have the heat shield, ETKA says to fit it with the new unit.

[jumpjetguy]

If you don't have the heat shield, ETKA says to fit it with the new unit.

Thank you Crasher, i will be sure to do as ETKA directs and fit the retro mod heat shield to the vacuum actuator on the EGR cooler assy.
Strange it came with one fitted on the turbo vacuum actuator,but not down below in close proximity to EGR exhaust pipework.Maybe they had instances of the heat degrading the vacuum actuator diaphragm or abs plastic body. Love the pic of the old Vulcan,i saw it flying on its farewell tour close to Warton Lancashire.When i first went on the spanners as an apprentice this is what i worked on, the good old English Electric Canberra circa 1977.Will get under the car later today and vacuum check the EGR cooler actuator.However i think the most people suffer fault codes, related to the Electric operated type Sickle valve.Which acts against the open close plunger type valve on the EGR.Screenshot (191).jpgScreenshot (192).jpgScreenshot (193).jpg
Canberra_T.4_.jpg