Wheres the ERG in 2012 Audi A6 SE TDI

[davlin]

Hi All,
Just got an 2012 Audi A6 SE TDI after departing with my VW B5 2004 Passat after 14years and 280k miles. I'm not sure what type of engine I have. it says Type 4G in the registration book (Pamphlet), she doesn't have a dipstick if this is any help in recognition. I'm coming up with P0404 code and I'm wondering if the ERG needs cleaning. She has done 168K miles but a lot of these was done taxiing and the last few years she was only driven to work and back a round trip of 10miles in traffic so I think she is bunged up with carbon.
How hard is it to do?

[stuart]

Crasher can you assist with this :)

[johnsimcox]

You don't say if it s 2 litre or 3 Litre. If it is 2 litre then it is an EA288 with 177bhp. The 4G reference is the model code for 2011-2019 version of the A6 also referred to as the C7 (not that Audi wants to confuse anyone!)

[Johnny31]

OP, what's the engine (2.0tdi, 3.0tdi, 3.0tfsi...)? You need to give us something at least... :)

Sent from my mobile...

[davlin]

Hi Johnny31,
Sorry for not replying sooner. She is a A6 limo TDI 2.0 R4 130KW 4G2 OTC if this makes any sense. I'm taking this info for the Audi Service schedule booklet and the sticker in the back of the front cover.

[davlin]

Hi johnsimcox,
Sorry for now replying back to you and Johnny31 sooner. She is a A6 limo TDI 2.0 R4 130KW 4G2 OTC if this makes any sense. I'm taking this info for the Audi Service schedule booklet and the sticker in the back of the front cover.

[johnsimcox]

Hi johnsimcox,
Sorry for now replying back to you and Johnny31 sooner. She is a A6 limo TDI 2.0 R4 130KW 4G2 OTC if this makes any sense. I'm taking this info for the Audi Service schedule booklet and the sticker in the back of the front cover.
That is the EA288 engine with 177bhp. Can't answer the question about the ERG but I sure someone else will give you that information shortly

[janakson]

Your car should have an EA189 engine, luckily the EGR is not too bad to access and just to the left of the engine.

They are supposed to be swapped out although I cleaned my valve and cooler two weeks ago and the car seems perfect so far.

37057

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[davlin]

Thanks janakson,
That's her ok, just checked your photo against my engine. What do you need to remove to clean her out. Is it a case of buying a Hayes workshop manual and taking it apart or is there, dare I say a YouTube video?

[johnsimcox]

DOn't think you will find a Haynes manual for the A6.

[johnsimcox]

Your car should have an EA189 engine, luckily the EGR is not too bad to access and just to the left of the engine.

They are supposed to be swapped out although I cleaned my valve and cooler two weeks ago and the car seems perfect so far.

37057

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clearly I was wrong and now I think about it my first C7 was affected by the recall, albeit that I changed it before I was notified

[davlin]

One of my replies said that you can't get a Hayes workshop manual for a A6.
have you heard of these guys?
37058

[davlin]

Is This a hard job to do. I'm a joiner by trade but I've been working on cars since I was 17. The last major job I done was pull the engine and gearbox out of a VW Passat and done the timing belt so I don't mind getting my hands dirty. Someone posted me when I enquired about a Hayes Workshop Manual and said there wasn't one, but I looked up the net and found a company called Emanuals.com. Ever heard of them and is it worth buying?
37059

[janakson]

Hi Davlin,

Sorry it's taken some time to get back to you. My car didn't display MIL/CEL or go into limp mode but did have an insufficient flow code. The job wasn't too hard considering it was the first non-service job I've done on the car. Removing and reinstalling the EGR+Cooler took about 4 hours of working casually. Cleaning the cooler cores and getting the gunk out of them however took almost a whole day. While there we also did the Throttle Valve (J338) and associated piping, Air Mass Meter (MAF) and air box.

You will need to start by confirming your exact EA189 engine - the engine code can be found on the PR code sticker. On our cars this is located in the spare wheel well. The sticker looks like the below;
http://wiki.ross-tech.com/wiki/images/a/aa/Pr_code_sticker_comments.jpg

The following parts list applies to engine codes: CGLC, CGLD, CMGB, CGLE

Audi Parts List:
G A13 A8J M1 - G13 Coolant 1.5L
03L 131 546 N - Gasket (x3) (Superseded - Orig. PN. 03K 131 547 C)
03L 131 547 D - Gasket
04L 131 547 S - Gasket (Superseded - Orig. PN. 03L 131 547 L)
070 131 548 C - Clip
03L 131 547 B - Seal
03L 131 120 A - Washer
Total Cost from Dealer: £73.57 inc. VAT

Usual Workshop Tools:
Various Ratchets
Torque Wrench
Socket Set
Hose Clip Pliers
Long Nose Pliers
Trim removal tool (Lock Carrier Cover)

Additional Tools/Consumables:
- STP EGR Cleaner 300ml or similar (x5)

- Long reach screwdriver (300mm x 5mm ) (Core diameter is 6mm)
sourcing map #1 Phillips Screwdriver 12 Inch Round Shaft Non Slip Comfortable Handle: Amazon.co.uk: DIY & Tools (https://www.amazon.co.uk/gp/product/B07D7CH6WN/)

- Long length Torx bits (100mm)
Torx Screwdriver Bits, Hakkin 9pcs S2 Steel 100mm T6-T40 Long Magnetic Star Torx Security Screwdriver Bits Set 1/4 Hex Shank: Amazon.co.uk: DIY & Tools (https://www.amazon.co.uk/gp/product/B01N8TJGLU/)

- Copaslip High Temperature Grease (In place of High Temperature Paste G 052 112 A3)

- Tape to mask off holes + Bungs to block coolant lines (or DIY it on the day)

Procedure:
We followed the procedure described in VW's ELSAWin software, unfortunately it is against forum rules to share this material on here. ELSAWin/ERWIN are the workshop manuals you are referring to.

Feel free drop me a PM and I can send these over to you. Alternatively you can get a temporary subscription to ERWIN using https://erwin.audi.com/erwin/showHome.do which will allow you to download the necessary documents.

We deviated from the procedure by not draining all the coolant - instead we covered off the DPF/Turbo and electrical connectors in the area so that they didn't get wet and bunged the coolant lines as soon as its disconnected. There will be coolant in the cooler so keep it steady when removing it, there are some cables in the way towards the front of the engine so this will need to be held to the side while removing the cooler.

Once the EGR+Cooler assembly is removed there are 6 bolts that need to be removed and the two will separate. There is a gasket in the assembly that you will need to keep and reuse, I was unsuccessful in finding a replacement gasket.

We cleaned the cores by repeatedly spraying EGR cleaner in and then pushing the carbon through with the long screwdriver. The cores go straight through to the bottom and do not form a U bend. You will want to keep the screwdriver or file straight so as not to breach the side walls in the cores - I don't know the exact construction but I imagine this could cause a coolant leak?

Once we got as much as possible out, any water we put down the cores came out clean. We waited for it to dry and then hit it with an air line until the air coming back out was also clear.

On restart the car no longer had an insufficient flow warning and drives exactly the same with no issues.

The following YouTube links may also come in handy;
Audi Q5 Tdi 2014 CGLC - EGR & intake clean Part1 - YouTube (https://www.youtube.com/watch?v=QlLTJ8yHABk)
Audi Q5 Tdi CGLC - EGR & intake clean part2 - YouTube (https://www.youtube.com/watch?v=pToq6oPvBwU)