Service Done Intake cleaned

**2fquick** · 28-07-2013,10:40 AM

Done my first service on 3.0 TDI QuattroDiesel, Oil, Air & Pollen filters
Upper intake manifold, throttle body & adaptor cleaned.
EGR ports in adaptor 1 completely blocked, other down to 1/2 size
Hopefully this will fix the code below
001025 - EGR System
P0401 - 002 - Insufficient Flow - Intermittent
Freeze Frame:
Fault Status: 00110010
Fault Priority: 0
Fault Frequency: 4
Mileage: 213324 km
Time Indication: 0
Date: 2013.06.17
Time: 14:14:48
Freeze Frame:
RPM: 2205 /min
Torque: 159.9 Nm
Speed: 124.3 km/h
Duty Cycle: 51.8 %
Duty Cycle: 20.9 %
Mass Air / Rev.: 552.3 mg/str
Duty Cycle: 51.7 %

PS
Why doesn't the return key create a new line on this forum, windows 8 IE10?

**Guest 2** · 28-07-2013,10:48 AM

How much did it all cost?

Re IE -

Originally Posted by mycarsavw

Post #12 has the solution for those stuck with IE - VW AUDI Forum - VWAF

**gupsterg** · 28-07-2013,01:38 PM

Originally Posted by 2fquick

Done my first service on 3.0 TDI QuattroDiesel, Oil, Air & Pollen filters
Upper intake manifold, throttle body & adaptor cleaned.

You're really giving that car some TLC's after all the bits you've been doing

...

Originally Posted by 2fquick

EGR ports in adaptor 1 completely blocked, other down to 1/2 size
Hopefully this will fix the code below
001025 - EGR System
P0401 - 002 - Insufficient Flow - Intermittent

It will

... as Audi TPI / TSB have same resolution for above fault code

...

Technical product information	Transaction No.: 2013297/6
Entry: exhaust recirculation flow too low - V6 2.7 l TDI, 3.0 l TDI	Release date: 14-Sep-2011

Customer statement / workshop findings

Engine warning light on. No running problems. The entry P0401 exhaust recirculation system through-flow too small is logged in the memory of the engine control unit.

Technical background

1. With increasing mileage the two small openings in the throttle valve adapter (aluminium ports, see illustration with arrow ) can clog up with soot.

2. Leaking vacuum pipes or leaking components.

Production change

---

Measure

1. Remove the electric throttle valve and check for coking. Check whether the two openings are clogged up. If they are, replace the component.

If the openings are not clogged up, check the following components.

2. Check the following parts with a hand vacuum pump. Mechanical EGR valve - for example: Membrane leaks, valve stiff, switch unit on the EGR cooler - for example: Membrane leaks, vacuum reservoir - for example: housing leaks. Flap in the air filter housing (in the A6 only). For example: Membrane leaks. Check all vacuum pipes for animal bites and chafe marks.

I know you saw my EGR thread due to clicking like/thanks and mine was practically blocked but I never got that fault code and I know you have an early A6 V6 3.0 TDi Avant like mine ....

I've yet to clean upper intake but was gonna use some bottle cleaning brushes what did you use?

**2fquick** · 28-07-2013,02:09 PM

Re How much did it all cost?
503440870 1 Bosch Fuel Filter 45.54..
501440390 1 Bosch Oil Filter 11.40
507440380 1 Hengst Pollen Filter 10.44
521776091 2 TRIPLE QX Engine Oil5w30 Fully Synthetic (For VAG applications) Engine Oil 5Ltr 83.98
104441548 2 Pagid Brake Disc 90.00
101441178 1 Pagid Brake Pads 34.74
202440385 1 Dayco Drive Belt 28.20
502440780 1 Premium Quality Air Filter 21.90
£330 - 30% hot30 discount, £230
Did not fit the rear discs & pads as 6.5mm left on pads
Looks like new Audi discs on the back with a Jan2011 date code on the paper sticker
I think I will be able to get at the lower calliper bolt with an 18mm deep ring spanner
Took the pollen filter back & got an Audi one.
Interestingly, this car has only been serviced by Audi, but only 1 pollen filter was fitted.
Thanks for the TSB & IE info
what would I do without you guys

**gupsterg** · 28-07-2013,02:33 PM

Originally Posted by gupsterg

I know you saw my EGR thread due to clicking like/thanks and mine was practically blocked but I never got that fault code and I know you have an early A6 V6 3.0 TDi Avant like mine ....

I earlier forgot to add what software is your ECU?

Originally mine from factory was this:

-------------------------------------------------------------------------------
Address 01: Engine Labels: Redir Fail!
Part No SW: 4F0 910 401 L HW: 4F0 907 401 A
Component: 3.0L V6TDI G000AG 0040
-------------------------------------------------------------------------------

Then due to a TSB relating to idle issue I had this flashed to it ...

-------------------------------------------------------------------------------
Address 01: Engine Labels: Redir Fail!
Part No SW: 4F0 910 401 A HW: 4F0 907 401 A
Component: 3.0L V6TDI G000AG 0020
-------------------------------------------------------------------------------

Then finally I had the last version ie latest flashed ...

-------------------------------------------------------------------------------
Address 01: Engine Labels: Redir Fail!
Part No SW: 4F0 910 402 L HW: 4F0 907 401 A
Component: 3.0L V6TDI G000AG 0020
-------------------------------------------------------------------------------

Red text is SW part no and revision is the numbers ...

Originally Posted by gupsterg

I've yet to clean upper intake but was gonna use some bottle cleaning brushes what did you use?

Any answer on above mate ...

Originally Posted by 2fquick

I think I will be able to get at the lower calliper bolt with an 18mm deep ring spanner

You may wanna pay some one or you may find ring spanner not fit/get enough leverage ...

My method was Link:- Rear Disc Change

**2fquick** · 28-07-2013,02:56 PM

Looks like Audi have reflashed it during service

Address 01: Engine Labels: Redir Fail!
Part No SW: 4F0 910 402 L HW: 4F0 907 401 B
Component: 3.0L V6TDI G000AG 0020

I'll try the ring spanner & if its not going to move, take it to my independent before I damage the head.
I don't mind paying, but like to see what condition everything else is in while doing a job.
While I was changing the oil I under-sealed the all the parts I could reach

**gupsterg** · 28-07-2013,03:21 PM

Cheers for your ECU info

I checked my VCDS logs and I did not have latest revision of SW when the ports were blocked perhaps that's why I never got a fault code

...

I hope this not come across in bad way

but for 3rd time how did you clean top intake manifold?

...

For speed I bought a used one and going to clean that before hand as I wanna decoke the swirl manifolds (lower section) as well, how coked up were your swirl manifolds?

Also what service regime had the car been on before you bought it long life or yearly?

Thanks

...

**2fquick** · 28-07-2013,04:36 PM

Sorry missed that bit,
Brake cleaner, screwdrivers, small wire brushes, coat hanger, 3x6 scotch-brite hand pads.
Tea (messy & boring)
Scraped everything I could reach, made a puck out of the SB pads & pulled through with the coat hanger.