EGR replacement DIY VW T6 2.0 CXGB engine mono turbo

[Lucasimo]

I am seriously considering replacing my EGR valve soon myself after getting the repeating P0401 Insufficient flow fault. I suspect it is gunked up and due for replacement.

From doing some research on here I reckon I can do it as I have a good sized driveway to work on the van and I have done major work on my previous van and cars before.

Hopefully I can do it on a weekend!

Just wondering if there's any particular top tips anyone has on this subject? I am considering getting a new EGR valve and associated front and rear pipe from my nearest dealer.

 

[Dellmassive]

DSG or manual?

The gearbox cooler needs disconnecting on a DSG.

Get some hose clamps to limit the coolant loss.

And you need VCDS/other scan tool to run the new EGR adaption and coolant bleed.

Just had mine done at the dealer and that that was in the report.

 

[Lucasimo]

DSG or manual?

The gearbox cooler needs disconnecting on a DSG.

Get some hose clamps to limit the coolant loss.

And you need VCDS/other scan tool to run the new EGR adaption and coolant bleed.

Just had mine done at the dealer and that that was in the report.

Hi, bit of a late reply on this. So it's a manual CXGB engine with monoturbo. EGR is part number 04L 131 512 T. I have VCDS which can do up to 2023 and a proper cable with unlimited VINs. There's a tricky bolt to remove on the EGR cooler which I'm not looking forward to. Someone on here said remove the starter motor as this makes access from the bottom easier so I'll do that for sure. I am hoping I won't need to take the whole bumper off as that will add a lot of time on the job. I think it should be possible to do it without all that faff. It's just that tricky bottom bolt which is a pain.

 

[Longers]

If anyone comes across this in future… some tips:

Yes, take starter motor off, makes taking the bottom bolt under cooler off much easier from underneath. Taking starter out isn’t too difficult - disconnect battery first!

Also take coolant bottle and windscreen washer tube out and fuel filter an housing out. Easy jobs to do.

You can just get the EGR off without taking the DSG cooler off. But you need to take the studs out from th EGR valve. VW have replaced studs and bolts with just a bolt design. They can supply. Makes putting it back on much easier. Once studs are off there is just a half inch rubber pipe between the block and the Egr which can be cleared, just. Worth having spare cooler seals ready though if you need to move it.

No need to take bumper off. Would have to take whole rad pack off to make a difference and it’s not needed.

Label everything you disconnect - there’s lots!

Have small hands!!!

Not a great job but worth it if you can to save at least £1000 in labour! It is just nuts, bolts and a few electrical connections