Passat 1.6 TDI p0407

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Originally Posted by UMEL

Did you test the old plugs and have you tested the new.

It might not be the first time a new plug is faulty.

How to Test Diesel Glow Plugs | YourMechanic Advice

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I didn't test the new ones I will do that today.
The garage it was originally at said one of the plugs were bad so just decided to do all

You did not do the work yourself ? Hmmmm cynical me, did they fit new plugs.

I had one fail last year which showed up as the engine management light only. One plug was high resistance. I just renewed them all with Bosch plugs.

So the EGR unit has been replaced?

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Originally Posted by UMEL

You did not do the work yourself ? Hmmmm cynical me, did they fit new plugs.

I had one fail last year which showed up as the engine management light only. One plug was high resistance. I just renewed them all with Bosch plugs.

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The garage was useless they said one had gone bad but didn't replace at all it was with them for 1 week for the none starting and came out with the EGR error (glow plug light on etc) they claimed nothing was wrong with it. And the missus drove it home, a hour later she drove it and it was in limp mode/flashy glow plug light.
I got back from work to scan a p0407 error

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Originally Posted by Crasher

So the EGR unit has been replaced?

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Yes new borgwarner unit in.
I'll try get a video of the startup when I get back from work.

I have also tried blocking off the EGR with a thin bit of aluminium but the car behaved exactly the same with it blocked and not (I've removed it now).
It feels like the car is gonna stall for a split second like it's being starved of oxygen or fuel

At the beginning of your post you mentioned noises from the throttle body.

It does click & whir on start-up & shut-down, but does have plastic gears inside that can strip & cause further noises.
The flap then doesn't sit in the correct position, so can starve the engine of air.

Might be worth checking the plastic gears are not chewed up, although it should be flagging up a different fault code.

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Originally Posted by philipharmes

At the beginning of your post you mentioned noises from the throttle body.

It does click & whir on start-up & shut-down, but does have plastic gears inside that can strip & cause further noises.
The flap then doesn't sit in the correct position, so can starve the engine of air.

Might be worth checking the plastic gears are not chewed up, although it should be flagging up a different fault code.

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I have had that off to check but it seemed ok nothing worn down and since the EGR change it has got a lot less noisy to the point it was before.

Which EGR cooler was fitted?

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Originally Posted by Crasher

Which EGR cooler was fitted?

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The Borgwarner EGR

Took some videos you can see the timing of it off the clock, at the very end of the last video you can see the idle blip I'm talking about.

Passat egr error - YouTube

Passat egr no fault - YouTube


The one thing I have noticed today is a funny smell coming from the car which is hard to describe.. it's like gas or electrical smell