EGR Valve

[Carpinus]

Caravelle Generation 6 DSG 204 November 2016. 22000 miles.

Started vehicle and found the glow plug warning light flashing and the engine management light on - also stop/start error shown on MFD. Visited a local garage for a diagnostic read of the fault codes and returned code P040100. They cleared the codes and they stayed off when in the garage. However, the engine management light came on soon after leaving the garage. This wasn't a VW dealer as there are none where I live. I am now left wondering what my next move is?

Can I still drive the vehicle it doesn't appear to be in limp mode?
Can I remove and clean the EGR myself and are there any help diagrams etc on the forum?
I have seen EGR cleaners you spray into the engine, but I cannot think that would help much?
If I have to have the EGR replaced by VW what would be the expected cost?
On the 12/11/19 following a recall reference 23Y7 a 23Z7 engine control unit was updated. It goes on to say this will have no detrimental effect on fuel consumption, CO2 emissions or loss of engine performance etc. Also, I was given several free adblue top ups at the time, I am wondering if this has lead to more sooting up in the EGR?

If any of the forum specialists could help I would be most appreciative. Twentytwo thousand miles and EGR problems seems very wrong.

 

[Loz]

Vw T6 102 EGR swap?

Hi guys, I've got a T6 102 which is showing an EGR fault on Carista but nothing on the dash. driving - under load at 60/70 when holding the throttle at a set point, after a minute or two the van will begin to lose power. Simply lifting off and back on the throttle clears the issue, as does...

www.t6forum.com

 

[DXX]

You have insufficient flow through the EGR system, IMO the magic sprays and in place flushes are a waste of time. 22K miles is very low, but unfortunately not a rare problem. You could try a VW main dealer and see if you get any ‘goodwill’ work carried out.
I have just cleaned a T6 EGR system with more than 100K and the cooler was 100% blocked, flap valve partially seized requiring approx 4x the vaccum to operate it than after cleaning.
If you use the Search function you’ll find the replacement costs experienced, from memory just over £1000 with labour.

 

[Phil Blackburn]

What driving have you done over the last few months ?
I had all the same issues a few months back, same van and similar mileage, i cleared the faults a few times as i was certain that there was not a fault but it kept coming back after a few days.
it wasn't doing many miles and all of it around town so I did a forced regen via Carista and took it on a good run on a quiet motorway for an hour or so and i've had no issue's since.

 

[Loz]

What driving have you done over the last few months ?
I had all the same issues a few months back, same van and similar mileage, i cleared the faults a few times as i was certain that there was not a fault but it kept coming back after a few days.
it wasn't doing many miles and all of it around town so I did a forced regen via Carista and took it on a good run on a quiet motorway for an hour or so and i've had no issue's since.

REGENS are for the DPF and won't help the blocked EGR Cooler

 

[Phil Blackburn]

REGENS are for the DPF and won't help the blocked EGR Cooler

Good point sir,
i'm sure the fault code was the same on mine and also exactly the same warning lights

 

[Carpinus]

Vw T6 102 EGR swap?

Hi guys, I've got a T6 102 which is showing an EGR fault on Carista but nothing on the dash. driving - under load at 60/70 when holding the throttle at a set point, after a minute or two the van will begin to lose power. Simply lifting off and back on the throttle clears the issue, as does...

www.t6forum.com

Many thanks Loz, I'm afraid it wasn't a joy to read, a complicated and expensive procedure.

 

[Carpinus]

You have insufficient flow through the EGR system, IMO the magic sprays and in place flushes are a waste of time. 22K miles is very low, but unfortunately not a rare problem. You could try a VW main dealer and see if you get any ‘goodwill’ work carried out.
I have just cleaned a T6 EGR system with more than 100K and the cooler was 100% blocked, flap valve partially seized requiring approx 4x the vaccum to operate it than after cleaning.
If you use the Search function you’ll find the replacement costs experienced, from memory just over £1000 with labour.

Many thanks for your comments DXX. It seems to me as this is a serviceable part it should be easy to remove and replace at at a reasonable price. I wonder if it would be as expensive on a transit van? Never the less, where am going to find £1000 plus after Christmas!

 

[Carpinus]

What driving have you done over the last few months ?
I had all the same issues a few months back, same van and similar mileage, i cleared the faults a few times as i was certain that there was not a fault but it kept coming back after a few days.
it wasn't doing many miles and all of it around town so I did a forced regen via Carista and took it on a good run on a quiet motorway for an hour or so and i've had no issue's since.

Thanks Phil, I must admit to short trips and low mileage. However, the DPF light hasn't been on and I have learnt to know when a run is required for regeneration.

 

[DXX]

Many thanks for your comments DXX. It seems to me as this is a serviceable part it should be easy to remove and replace at at a reasonable price. I wonder if it would be as expensive on a transit van? Never the less, where am going to find £1000 plus after Christmas!

If you have another vehicle to use you could try removing and cleaning.
It’s guaranteed to block on all vehicles, the variable is how many miles. I think it’s worth a visit to VW Customer Services at just 22K miles, they can only say no.

 

[Carpinus]

At present I am left wondering what the EGR's function is. It seems many people on the forum feel you are better off without it, better fuel economy and power output. However, I don't know the effect on emissions but wouldn't think it was much especially as they get older and caked with soot. However, I suspect any tampering with EGR function would invalidate your future MOT's. Would be interested to here what other peoples views are.

 

[Carpinus]

If you have another vehicle to use you could try removing and cleaning.
It’s is guaranteed to block on all vehicles, the variable is how many miles. I think it’s worth a visit to VW Customer Services at just 22K miles, they can only say no.

Thanks DXX, I live on the Isle of Wight so a visit to VW means a boat trip to Southampton where all my van servicing is carried out. I have found in the past trying to deal with a problem over the phone is quite difficult - still I will press on.

 

[Ali-G]

At present I am left wondering what the EGR's function is. It seems many people on the forum feel you are better off without it, better fuel economy and power output. However, I don't know the effect on emissions but wouldn't think it was much especially as they get older and caked with soot. However, I suspect any tampering with EGR function would invalidate your future MOT's. Would be interested to here what other peoples views are.

I had EGR problems, last year and booked my van into a local independent VW specialist. They suggested an EGR delete and assured me that I would have no problems with future MOT's.
Well yesterday the van went for it's first MOT since the delete and passed with no problems.
See below the testers remarks on the emissions test.

 

[Loz]

I had EGR problems, last year and booked my van into a local independent VW specialist. They suggested an EGR delete and assured me that I would have no problems with future MOT's.
Well yesterday the van went for it's first MOT since the delete and passed with no problems.
See below the testers remarks on the emissions test.
View attachment 141964

That’s good, what “delete “ did they do? software,shim, other?

 

[Ali-G]

That’s good, what “delete “ did they do? software,shim, other?

I'm not sure to be honest Loz, next time I go there I'll ask.

 

[Mooncat]

I had EGR problems, last year and booked my van into a local independent VW specialist. They suggested an EGR delete and assured me that I would have no problems with future MOT's.
Well yesterday the van went for it's first MOT since the delete and passed with no problems.
See below the testers remarks on the emissions test.

That's common for pretty much any vehicle with a DPF fitted. It's usually referred to as a fast pass.

 

[Carpinus]

I had EGR problems, last year and booked my van into a local independent VW specialist. They suggested an EGR delete and assured me that I would have no problems with future MOT's.
Well yesterday the van went for it's first MOT since the delete and passed with no problems.
See below the testers remarks on the emissions test.
View attachment 141964

Thanks Ali-G, that is the first piece of positive information I have received since my EGR problem appeared. However, you will have to explain to me what a EGR Delete is?
I am assuming this is where the EGR is blanked off by a plate, but what happens to the cooler? Does it stay in situ or removed? Also having carried out this work is a re-map required? I have read somewhere that without the EGR the exhaust gasses are cleaner and leads to less regenerations at the DPF.

If there is anybody on the forum that specialise on EGR issues a comment would be appreciated.

 

[Ali-G]

Thanks Ali-G, that is the first piece of positive information I have received since my EGR problem appeared. However, you will have to explain to me what a EGR Delete is?
I am assuming this is where the EGR is blanked off by a plate, but what happens to the cooler? Does it stay in situ or removed? Also having carried out this work is a re-map required? I have read somewhere that without the EGR the exhaust gasses are cleaner and leads to less regenerations at the DPF.

If there is anybody on the forum that specialise on EGR issues a comment would be appreciated.

Sorry, I can't really answer your questions, as I replied to Loz, I'm not sure how they did it.
I had an intermittent EML light coming on and when the garage investigated they found that the EGR was faulty.
They gave me the choice of replacing it for around £1000 or deleting it for around £250.
They said that I would have no problems with any future MOT's and that I would have no further problems with the EGR so it was a "no brainer" as far as I was concerned.

 

[Carpinus]

Sorry, I can't really answer your questions, as I replied to Loz, I'm not sure how they did it.
I had an intermittent EML light coming on and when the garage investigated they found that the EGR was faulty.
They gave me the choice of replacing it for around £1000 or deleting it for around £250.
They said that I would have no problems with any future MOT's and that I would have no further problems with the EGR so it was a "no brainer" as far as I was concerned.

Thanks Ali-G.
The only VW dealers local to my area are main dealers and I'm sure wouldn't they wouldn't carry out the EGR delete! If anyone knows a garage in the Southampton area please let me know.

 

[superflyguy]

I had a new egr valve replaced 8 months ago, it failed on me last week and I've found out the one fitted was a non genuine item, this wasn't done at a main dealer but a large local commercial vehicle garage. I had a few problems with the garage so decided not to take it back to them as the previous visit I nearly dragged the workshop manager over the counter !!
Just had a genuine egr fitted and if this one decides to fail or block I will be having the egr blanked off !! My mechanic blanked it off while I was awaiting the part to arrive and it drove fine . Regarding the old one I couldn't believe how much it had blocked over 8 months.