AZD engine (1.6 16V petrol) - EGR basic settings cannot be performed (adaptation error every time)

[crok]

Hi Community!


You are my last and only hope I think..

I have a Seat Toledo (2002) with an AZD engine
(1.6 16V petrol, same as in Golfs and Boras).

My EGR valve was faulty and has been replaced with a new one
but I cannot adapt the (brand new..) EGR valve, it always fails,
says "ERROR" when I try to adapt it in VAG-COM and I have the
following code in the ECU:

17812 - EGR System: Basic Setting not Performed
P1404 - 35-00

Voltage is 12.4V, coolant is around 40°C (did not start the engine yet).
No electrical consumers are on during adaptation process
(headlight, window defogger, et cetera)..

When I do the adaptation I do hear and feel the clicking of the valve.
When I do an output test I do hear and feel the clicking of the valve.

I'm using VAG-COM 409.1 full version (yes, it's old ..)
but I tried it with VCDS and AutoCOM as well - no joy.

Is there any trick to do the adaptation? What can be the issue?


Regards and thank you for your answers in advance!



Cr0k

[crok]

Any idea, girls and guys? No hope? Come on..!

[Crasher]

Which adaptation value are you using?

[crok]

Which adaptation value are you using?

I used the Ross-Tech instructions (Meas. Block 074).
Exhaust Gas Recirculation (EGR) Valve Adaptation - Ross-Tech Wiki

..or what do you mean by adaptation value?

[Crasher]

It is Basic settings 074, not measuring blocks. When “ADP OK” is shown in Basic Settings 074 Zone 4, start the engine and go to Basic Settings 075, give the engine 5 short bursts of revs to the max and the value in Zone 4 should change to “Test ON” and then let it idle until it says “SYS OK” but sometimes it is necessary to do this test on the road with the engine on trailing throttle in a high gear.

[crok]

It is Basic settings 074, not measuring blocks. When “ADP OK” is shown in Basic Settings 074 Zone 4, start the engine and go to Basic Settings 075, give the engine 5 short bursts of revs to the max and the value in Zone 4 should change to “Test ON” and then let it idle until it says “SYS OK” but sometimes it is necessary to do this test on the road with the engine on trailing throttle in a high gear.

..and here comes my issue: no matter how and how many times I try to do the adaptation in basic settings (channel 074) it always saying "FAIL" - so this is my issue.

[crok]

For the record: a Pierburg 7.28248.17.0 EGR valve solved the issue. Thank you, Crasher!

[Crasher]

One of my young mechanics recently bought a 2002 Leon with the AZD engine and it had been taken off the road because the previous owner could not get it to run. I got him to take home a new EGR valve and the VCDS cable and he fitted it at home and it ran fine for a while and then went loopy again. He got it into work and I could tell it was EGR just listening to it, we took off the new valve and operated it off the car at which point a piece of ferrous metal fell into view in the port. On the workshop system there is a warning about cast iron swarf from the exhaust manifold entering the valve but that was for new cars, it had taken 15 years for this piece of swarf to get into the valve.

[crok]

This information makes me curious - I mean you have 30+ years of experience (as far as I know) in VW and you tell me the same as some others in my community in Hungary and Eastern-Europe.. Russia!.. This metallic piece of swarf.. stuck into the EGR valve.. Me and lot of members in the hungarian community have experienced this phenomenon, and also I saw a video from a russian guy on Youtube who has removed the exhaust manifold and shows the issue: GOLF 4 Bora AZD 1.6 V16 ИЗ ЗÐ� КÐ�ТÐ�ЛИЗÐ�ТОÐ*Ð� ПОÐ*Ð’Ð�ЛО ГÐ*Ðœ - YouTube Yes, I know the pieces are coming off of the end of the manifold in the video but I tell you we all saw the same shape, size and colour of metallic swarf.. in the EGR valve.. so somehow it got escape on the EGR port on the manifold (turbulence in the manifold? God knows..)

So you have a young mechanic there with a car that has an AZD engine? Can I somehow get in contact with him? I would like to ask him to do me a favor and give me some values from his car.

[Crasher]

Yes it was bizarre that we found this big chunk of ferrous metal in the brand new Pierburg EGR valve, it was old burnt and rusty so it must have come from the inside of the exhaust manifold

So you have a young mechanic there with a car that has an AZD engine?

His name is Leon and he drives a ..... Leon....

This is the TPI as provided by Seat