EGR cooler fault golf 1.6 tdi

[Liboyj]

New to the site today, advice and help please......
My 59 plate vw golf 1.6 tdi went in for a main dealer service 3 weeks ago, we said that the glow plug lamp kept coming on with loss of power. Advised that this was not part of service and for £60 extra they could diagnose issue. Informed that the Egr cooler needed replacing circa £1000.00' although after a moan Vw picked up cost of cooler and 50% of labour! leaving me with about £350 to pay. Groan but what must be......
Booked in today for repair, received a phone call to say all done, but have found further issues, split EGR pipe, leaking exhaust manifold, massive oil leak (dealerships words) and oil pressure switch needs replacing! Bearing in mind it had a full service 3 weeks ago and gas cover about 500 miles since I found this a bit shocking, VW dealership thought otherwise!
I'm no engineer, but something doesn't ring right here, any comments welcome.

[Keithuk]

Welcome to the forum.

Its out of warranty so you can Contact VW Customer Services (https://www.volkswagen.co.uk/about-us/contact) if its always been serviced by VW, and give them the story.

I ask new members only once to add their car spec to their signature as all regular members do this.

[matthew2riches]

That really does sound terrible! How many miles have you done and what kind of life has the car had?

[Horizon]

That really does sound terrible! How many miles have you done and what kind of life has the car had?
it sounds like your dealer either mis diognosed the EGR cooler fault, dealer techs now solely rely on the computer diognosed codes and take them as gospel. The. EGR pipe being split will throw the same error code a a split cooler, and they have changed the wrong part. Or they have damaged the pipe and whatever else whilst changing the cooler and you are picking up the bill.
This is my opinion only.

[Mal]

I had the coil warning light on and the car going into limp mode about 3 time before Christmas, the car has only done 29500 miles and is not 3years old until next May.
I booked the car in for a check on 2nd Jan picked up lunch time today with the EGR Cooler changed, on the job sheet it says the price of the EGR cooler is £878.66, I am glad I didn't have to pay that and by the time the 2Year guarantee on it has ran out the car will be gone.... :approve:

[a8 tech]

egr valve is incorporated into the cooler and the failure of the valve is very common across all vag 1.6 cr engines

[Crasher]

We do loads of the EGR coolers, TPS keep about four in stock and often sell 2 a day! They are a total pig to fit compared to other EGR valves, they take a good four hours to do.

[a8 tech]

Trick is to leave the dpf in situ takes around 2 hours then and can also be done like this for 2.0 tdi quattro.

[Crasher]

I am glad you can do it with the DPF in situ on the 1.6 (OK on the 2 litre, yes), my forearms are too thick, you must be a slender little thing...

[CharW86]

My 2010 1.6 TDi had a service 4 weeks ago at 43k miles, two weeks later the car kept losing power, chugging and then cutting out completely when driving - EGR valve but since that was replaced it has since shut off whilst driving it as it did before with no warning lights, as if it has stalled whilst driving normally in third gear, for example. Does anyone know if this a known fault with the 1.6 TDi model as I am contemplating changing my car?

[Crasher]

Not a more common fault with that engine than with any other modern car. I suggest a fault code scan first.

[CharW86]

Ok, so it turns out three injectors had failed only 2 weeks after the EGR valve was replaced...VW only agreed to pay 70% of the BIG bill. Apparently there's a recall on injectors for the 2.0l but not for this model!

[N1CK]

Similar sort of issues with our 1.6 TDI - No warning lights - Loss of power (initially started but nothing responding to accelerator) attempted to drive it and it'll just stall. RAC called to rescue us hooked up his laptop and surprise no faults showing. He asked me what garage we used towed it there to be told it needed looking at by a diesel specialist so it went to DTM Bristol again they were miffed by it as they managed to start and run it(test drove with laptop hooked up) was severely underpowered and issues pointing towards either not enough air getting in or exhaust gasses not getting out. Next step remove air inlet manifold 3+hrs labour later turns out inlet manifold all coked up and not operating, all cleaned and back home. 3 weeks later wife driving to work and called me "this f*^*^*g car is stalling again luckily she was pretty much there and just needed to park. When she returned to the car it failed to start and once again just about managed to turn over run for 10 seconds if were lucky and stall. Im in the process of warming my hands up as i cannot afford to have specialist repair it again so going for it myself. Have removed all the diesel common rail and pipes and have the air inlet manifold exposed.
The RAC guy suggested the EGR is sticking in the open position and sending gasses back to the inlet manifold 100% of the time and not actuating as it should. I realise the EGR is a nightmare to get at and don't want associated costs replacing it but is there any additives i could try that would give it a total clean? Bought the car in Sept 2014 has 123,000 miles. Already used a bottle of Winns fuel additive but that was back in October and I don't want to keep adding this stuff as i was told not not to use more frequently than every 3 months. Nor do I want to strip the air inlet every few weeks!

2010 Passat 1.6 TDI Bluemotion - (with no motion!)

[Alex Gilroy]

Just got my 2010 golf 1.6 bluemotion back from vk specialists today Egr value all been replaced. I was out off warranty but after talks with vk we agreed they'd cover all the parts and id pay the Labour cost. And I've now got 2 years labour with it. I also got the water pump and belt done as it was due in march.

[Usedtolovemyvw]

My 2010 1.6TDI lost power suddenly on a country road - threw some blue smoke out of the exhaust, coughed and stopped. Engine would restart but not tick over and would not accept any drive gears. There were no warning lights. AA man came and said it was coked up - blanked off the egr valve so that it was driveable and advised me to take it for repair which may just mean cleaning out. Garage tell me the EGR cooler needs replacing at £917. When challenged he agreed it was a known fault with this model (they have the part in stock) and that I should expect parts failures after 6 years and there was no goodwill available - I disagree - I didn't buy a golf to be only reliable for 6 years and 80k miles. Garage is the VW dealership from which I bought it, it was serviced there 3 months ago and it has full VW service history. Any thoughts anyone? It has to be paid of course as I have to get the car back - but I was taken aback.

[Crasher]

The new car warranty is for 3 years which can be pushed with some goodwill if the car was bought from a VW dealer and serviced by them OR you can buy an extended warranty. When your warranty has expired, you have to pay for repairs, it's considered the normal state of affairs. If your EGR valve was covered at 6 years, image how you would feel upon hearing it had been done FOC if you were someone who had paid extra for this longer cover? If the EGR valve was covered, what next?

[zollaf]

if you want a car with a warranty, buy a brand new car with a warranty and change it after 3 years. alternatively buy a kia ceed with its 7 years warranty.

[Usedtolovemyvw]

Thanks Crasher - I have no problem with paying for repairs as they become due however it is clear from this forum and from the dealership itself that this is a known fault with the specific model. I've had other diesels with higher mileage and never had anything similar. Just disappointed.

[zollaf]

every car in the world has some sort of specific fault. do you expect to buy a car and never have to pay to fix it.

[zollaf]

but a grand for a part on a 6 year old car like this, a car that you would consider to be an economy car rather than a performance car, isn't good. but, so many things in life these days are like this..

[Crasher]

This valve (03L 131 512 CF which is now 03L 131 512 DQ) is used on the CAYB and CAYC 1.6 CR TDI and is made by Valeo if I remember rightly. A couple of companies are offering reconditioned units including a company near to us in Nottingham, how good they are I don’t know but the companies past reputation before its name change was, well, questionable to say the least. A new valve from VW is £321.92 including VAT so the price you have been quoted is a bit high. They take around five maybe six hours to change so they must be asking £100 ish per hour. The A1 is worse, it takes more than a day.

[sktan]

New to the site today, advice and help please......
My 59 plate vw golf 1.6 tdi went in for a main dealer service 3 weeks ago, we said that the glow plug lamp kept coming on with loss of power. Advised that this was not part of service and for £60 extra they could diagnose issue. Informed that the Egr cooler (http://www.commercialegrcooler.com) needed replacing circa £1000.00' although after a moan Vw picked up cost of cooler and 50% of labour! leaving me with about £350 to pay. Groan but what must be......
Booked in today for repair, received a phone call to say all done, but have found further issues, split EGR pipe, leaking exhaust manifold, massive oil leak (dealerships words) and oil pressure switch needs replacing! Bearing in mind it had a full service 3 weeks ago and gas cover about 500 miles since I found this a bit shocking, VW dealership thought otherwise!
I'm no engineer, but something doesn't ring right here, any comments welcome.

Have you ever consider egr delete?

[holmes.paul22]

Why do you all go to vag or skoda for services. I have a skoda Fabia 2 2012 1.6cr diesel. I have owned the car from New and serviced myself never has any light s on ever and I changed my glow plugs at 60k miles as glow plugs can speed up egr issues for 40 pounds of plugs not worth the hassle. Secondly I only drive 5 miles each way to work short journeys so I should have had a problem I drive hard and I take my car down the motorway and I don't use top gear. Cr diesels need to be driven hard and if the revs are not near 2500 rpm it is not running efficiently. Read the news don't trust Vag to act on your behalf. My car also has cheat software and it is staying that way don't trust them with your car. All the parts to service by yourself including fuel filter every service approx 85 pounds and takes 20mins to do. Warranty is not worth the paper it's on. Oh and the engine map by vag isn't great either so that may cause issues depending on how you drive. Everyone is different in driving style. I drive mine hard like a teenager on a promise and it runs sweet no problem. People stop being lazy and diy.

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