Hi everyone,

 

over the last 6 months I have been having intermittent issues with my car, about every 1000 to 2000 miles the car would go into limp mode with the glow plug light flashing with the code  P0403 00 registered on the computer. It did this about 3 times but now the frequency of these events is increasing to every few hundred miles. Am I correct in saying the EGR valve is failing and requires replacement? Also I heard the EGR valve gears can be replaced with it in situ which is much cheaper and less time consuming than removal and replacement. I would much appreciate people's opinions about how to fix this issue and have attached a VCDS print out with more information.

 

 

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CFFB)       Labels:. 03L-906-018-CFF.clb
   Part No SW: 03L 906 018 JB    HW: 03L 906 018 BR
   Component: R4 2.0l TDI   H22 9978  
   Revision: 42H22---    Serial number:                CVN: FF54D7C9
   Coding: 00190012042500080000
   Shop #: WSC 24066 210 00000
   ASAM Dataset: EV_ECM20TDI01103L906018JB 003004
   ROD: EV_ECM20TDI01103L906018JB.rod
   VCID: 73B3D1B70B3264A3C2D-8026
   VINID: 91D4925470E4A122400890C6188BC20C1B

2 Faults Found:
4891 - EGR Valve (N18) 
          P0403 00 [104] - Malfunction
          Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 3
                    Mileage: 140327 km
                    Date: 2022.08.30
                    Time: 09:37:38

                    Engine RPM: 2288.50 /min
                    Normed load value: 69.4 %
                    Vehicle speed: 112 km/h
                    Coolant temperature: 92 °C
                    Intake air temperature: 28 °C
                    Ambient air pressure: 1010 mbar
                    Voltage terminal 30: 14.220 V
                    Unlearning counter according OBD: 39
                    Air mass: actual value (mg/stroke): 535.6 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 100.00 %
                    EGR Solen.val.: actual value: 86.78 %
                    EGR valve: offset closed: 9.70 %
                    Actuator for high pressure EGR: status-Bits 0-7: 0
                    Actuator for high pressure EGR: status-Bits 0-7: 55
                    Actuator for high pressure EGR: status-Bits 0-7: 7
                    Actuator for high pressure EGR: status-Bits 0-7: 0
                    High press EGR actuator: actual unconditioned volt val: 1105.4 mV

4892 - EGR Valve (N18) 
          P0403 00 [096] - Malfunction
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 140327 km
                    Date: 2022.08.30
                    Time: 09:37:38

                    Engine RPM: 2288.50 /min
                    Normed load value: 47.5 %
                    Vehicle speed: 112 km/h
                    Coolant temperature: 92 °C
                    Intake air temperature: 28 °C
                    Ambient air pressure: 1010 mbar
                    Voltage terminal 30: 14.220 V
                    Unlearning counter according OBD: 37
                    Air mass: actual value (mg/stroke): 454.3 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 100.00 %
                    EGR Solen.val.: actual value: 2.75 %
                    EGR valve: offset closed: 9.70 %
                    Actuator for high pressure EGR: status-Bits 0-7: 0
                    Actuator for high pressure EGR: status-Bits 0-7: 55
                    Actuator for high pressure EGR: status-Bits 0-7: 7
                    Actuator for high pressure EGR: status-Bits 0-7: 4
                    High press EGR actuator: actual unconditioned volt val: 3627.2 mV

Readiness: 0 1 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 1K0-907-379-60EC1F.clb
   Part No SW: 1K0 907 379 BD    HW: 1K0 907 379 BD
   Component: ESP MK60EC1   H31 0108  
   Revision: 00H31001    
   Coding: 863D601609240003610E06EA901F0082300000
   Shop #: WSC 33361 790 00053
   VCID: 75B7EFAF05C67A93EC9-8020

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:| 5K0-907-044.clb
   Part No SW: 3T0 907 044 AR    HW: 3T0 907 044 AR
   Component: Climatronic   H15 0401  
   Revision: 00005001    
   Coding: 0000000002
   Shop #: WSC 33361 790 00999
   ASAM Dataset: EV_Climatronic A01006
   ROD: EV_ClimaAutoBasis_SK46.rod
   VCID: 025D847344885D2BD9B-8056

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 1K0-937-08x-09.clb
   Part No SW: 1K0 937 087 K    HW: 1K0 937 087 K
   Component: BCM PQ35  H+  103 0615  
   Revision: 00103 AD    
   Coding: 48990AB8A05BF1C040080080110081E4427000AE532081605C0040000040
   Shop #: WSC 33361 790 00999
   VCID: 392F239F695EDEF3C81-806C

   Subsystem 1 - Part No: 3T2 955 119 A  Labels: 1KX-955-119.CLB
   Component: Wischer 06101  26  0602 
   Coding: 00D7B7

   Subsystem 2 - Part No: 1K0 955 559 AH  Labels: 1K0-955-559-AG.CLB
   Component: RLS 121010 05  54  0403 
   Coding: 2730ED

   Subsystem 3 - Part No: 1K8 951 171 
   Component: DWA-Sensor 00  001 0104 

   Subsystem 4 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H05 1501 

No fault code found.

-------------------------------------------------------------------------------
Address 10: Park/Steer Assist (J446)       Labels:. 1Z0-919-475-V1.clb
   Part No SW: 1Z0 919 475 B    HW: 1Z0 919 475 
   Component: PARKHILFE 4K  H06 0006  
   Revision: --------    Serial number: 66641028120495
   Coding: 100004
   Shop #: WSC 33361 790 00999
   VCID: 40D94E7B0A848F3B8FF-8014

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 5N0-959-655.lbl
   Part No SW: 3T0 959 655 C    HW: 3T0 959 655 C
   Component: J234__LAU VW10 HI   1918  
   Revision: 20014000    Serial number: 003K2PLELG6%  
   Coding: 0016725
   Shop #: WSC 33361 790 00053
   VCID: 41DF4B7F0D8E8633801-8014

   Subsystem 1 - Serial number: 6332MTS670342770 

   Subsystem 2 - Serial number: 6342MTS670472770 

   Subsystem 3 - Serial number: 6351HTS6CRHGF9KJ 

   Subsystem 4 - Serial number: 6361HTS6P9GGF9KJ 

   Subsystem 5 - Serial number: 63727TS6SM7DF9KR 

   Subsystem 6 - Serial number: 00000000000000000

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:| 5K0-953-569.clb
   Part No SW: 1K5 953 521 AK    HW: 5K0 953 569 B
   Component: LENKS.MODUL   009 0136  
   Revision: FF010039    Serial number: 20101008201265
   Coding: 0082140000
   Shop #: WSC 33361 790 00999
   ASAM Dataset: EV_SMLSNGVOLWS A01004
   ROD: EV_SMLSNGVOLWS.rod
   VCID: 76B5E8A31840718BE53-8022

   Multifunction steering wheel control module: 
   Subsystem 1 - Part No SW: 3T0 959 537     HW: 3T0 959 537   Labels: 3C8-959-537.CLB
   Component: E221__MFL-URO  H07 0012 
   Coding: 800000

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 3T2 920 941 H    HW: 3T2 920 941 H
   Component: KOMBI         H20 0420  
   Serial number: 00000000000000
   Coding: 410B00
   Shop #: WSC 33361 790 00999
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04089
   ROD: EV_Kombi_UDS_VDD_RM09_SK46.rod
   VCID: 3A2D3C936CD8D5EBC1B-806E

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels:. 7N0-907-530-V1.clb
   Part No SW: 7N0 907 530     HW: 1K0 907 951 
   Component: J533  Gateway   H27 5603  
   Revision:   H27       Serial number: 111010F2001538
   Coding: E9A07F0600020200003303
   Shop #: WSC 33361 790 00999
   VCID: 6D87C7CF6196B253149-8038

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234 
   Component: IMMO          H20 0420  
   Serial number: 00000000000000
   Coding: 000000
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03008
   ROD: EV_Immo_UDS_VDD_RM09_VW21.rod
   VCID: 6A8DCCD35CF8A56B71B-803E

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:. 8X0-959-793.clb
   Part No SW: 8X0 959 793 C    HW: 8X0 959 793 C
   Component: TSG FA        H09 0409  
   Revision: --------    Serial number: --------------
   Coding: 011D0220D001001000
   Shop #: WSC 33361 790 00999
   VCID: 4DC7674FCDD65253749-8018

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1K0-909-14x-GEN3.clb
   Part No: 1K0 909 144 J
   Component: EPS_ZFLS Kl. 195    3001  
   Revision: 00H17000    
   Shop #: WSC 33361 790 00999
   VCID: 313F1BBFBD2E16B3701-8064

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:. 8X0-959-792.clb
   Part No SW: 8X0 959 792 C    HW: 8X0 959 792 C
   Component: TSG BF        H09 0409  
   Revision: --------    Serial number: --------------
   Coding: 011D0220D001001000
   Shop #: WSC 33361 790 00999
   VCID: 4CC16A4B36CC5B5B637-8018

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (J503)       Labels:. 5M0-035-1xx-56.clb
   Part No SW: 3T0 035 156 C    HW: 3T0 035 156 C
   Component: BOLERO        014 0029  
   Revision: -----28S    Serial number: SKZ4Z3K1125441
   Coding: 0D0004000004
   Shop #: WSC 33361 790 00999
   VCID: 2E0500C3A010094B6D3-807A

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left (J388)       Labels:. 8X0-959-795.clb
   Part No SW: 8X0 959 795 B    HW: 8X0 959 795 B
   Component: TSG HL        H06 0409  
   Revision: --------    Serial number: --------------
   Coding: 010C00200001001000
   Shop #: WSC 33361 790 00053
   VCID: 4EC56043C0D0694B0D3-801A

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right (J389)       Labels:. 8X0-959-795.clb
   Part No SW: 8X0 959 795 B    HW: 8X0 959 795 B
   Component: TSG HR        H06 0409  
   Revision: --------    Serial number: --------------
   Coding: 010C00200001001000
   Shop #: WSC 33361 790 00053
   VCID: 4EC56043C0D0694B0D3-801A

No fault code found.

End----------(Elapsed Time: 01:09, VBatt start/end: 12.1V/12.2V)-----------
 

 

 

 

 

My understanding of that log, is that it asked for 100% activation of the valve inside and was only given a few percent (actual)

 

Have you removed to check how much cack is on the valve?

 

Hi, no I have not yet removed the valve, wanted to get a second opinion before going through the tedium of removing it.

25 minutes ago, fabia88 said:

Address 01: Engine (J623-CFFB)       Labels:. 03L-906-018-CFF.clb
   Part No SW: 03L 906 018 JB    HW: 03L 906 018 BR
   Component: R4 2.0l TDI   H22 9978  

Not sure of your entire car history, but it would appear you have (or previous owner) the EA189 NOx emissions fix done in the past.

At some point your engine would have been on 6xxx version, and now on 9978

 

As you you can see from this table, even the NOx fix, has had fixes applied.

 

 

1 minute ago, fabia88 said:

Hi, no I have not yet removed the valve, wanted to get a second opinion before going through the tedium of removing it.

Before you go down this route and get messy, I seem to think there was many complaints of EGR valves going wrong post EA189, and they had to replace the EGR valves.

Not sure if this still applies or if the goodwill period has expired (assuming I am not barking up the wrong tree!)

I bought the car just over a year ago and the previous owner told me the emissions fix was done but couldn't tell me when, however that route may be a lost cause as I have been servicing the car myself so the goodwill warranty on emissions components may be void. Do you think it is worth going to the dealer to get the software updated ?

Given your symptoms and the everytime the fault occurs quicker, odds are high that it's a gummed up EGR valve.

 

Hopefully someone that fixes these car more than me (I am not a mechanic, but have replaced EGR and other bits) will be able to tell you if anything can clean it, or more than likely it's easier to replace.
Word of caution though about fault codes, it doesn't always mean the problem is in the part throwing up the fault codes.

2 hours ago, varooom said:

My understanding of that log, is that it asked for 100% activation of the valve inside and was only given a few percent (actual)

 

Have you removed to check how much cack is on the valve?

 

That is not the valve

its a big unit ( water cooled ) that goes right across back of the engine block.

unless you’ve just used that as an example 

My advice would be to replace it, I done it laying on my back on drive.

Its not really a bad job if yer mechanical minded but to go through it all to clean it and put it back isn’t worth it in my eyes.

It’s full of small tubes through the cooler when you split it ( that’s a gasket required) don’t know if it would be available separately.

I posted some pictures on this forum when I done it 

7 minutes ago, Snapper1725 said:

That is not the valve

its a big unit ( water cooled ) that goes right across back of the engine block.

unless you’ve just used that as an example 

You are correct, was used as example image of how manky they can get 🤝

Edited 9 September, 20223 yr by varooom

Trying to do a link 😤 and can’t delete 

Edited 9 September, 20223 yr by Snapper1725

Search for 

Glow Plug light flashing on this forum

 

its got pictures I posted and a YouTube link to changing valve with what it looks like inside 

5 minutes ago, Snapper1725 said:

Search for 

Glow Plug light flashing on this forum

 

its got pictures I posted and a YouTube link to changing valve with what it looks like inside 

https://www.briskoda.net/forums/topic/441688-glow-plug-light-flashing/page/2/?tab=comments#comment-5396908

3 minutes ago, varooom said:

https://www.briskoda.net/forums/topic/441688-glow-plug-light-flashing/page/2/?tab=comments#comment-5396908

Thank you 🙏 

Thanks for all the advice, I have removed the egr valve before when removing the exhaust manifold so I'm confident I can perform the task, just to check does anyone recommend a brand of EGR valve? Was looking on autodoc and saw a huge number of brands making them with prices ranging from £120 ish for ridex (never heard of this brand) to over £200 for some of the more well known brands. 

I don't suppose you know part number of what is currently fitted?

 

If you don't know, please PM VIN if you like and I shall try to look and see (this will also check if part has been replaced)

@fabia88 I have compiled as much information as I could for your car, here they are.

 

 

Your VIN PR code list (scrubbed last 6 digits)

TMBBE73TXB9------.pdf

 

 

This document from pages 131-065 shows you an overview of every choice that could be fitted for your VIN (as it left the factory, so does not show what has been superseded) So this gives you the exploded view that should be useful.

EGR 131-065.pdf

 

 

Part 05 - 03L 131 512 CF Cooler for exhaust gas recuperation with control flap has been superseded as I guessed it might have been to 03L 131 512 DQ

 

 

You also have the choice of buying new and binning the old one, or the possibility of an exchange part exists (with caveats as always)

 

 

And finally if we go to order the EGR Cooler/Valve, this gives us a large list or parts to replace (seals/bolts) and possible additional items associated.

Parts and Seals.pdf

You can reference this along with the EGR 131-065.pdf to see the part fitting locations.

Update: I have performed an egr valve test using vcds and it came back as successful which I find a little confusing considering the fact that I'm getting egr related fault codes. Also I was looking through some of the live data to see if there was anything abnormal and noticed that the temp sensor for the egr after cooler raw value was reading minus 270.6 degrees, that doesn't sound right, could it be this that is causing an issue?

Well it is indeed very close to absolute zero, maybe you have gotten closer to the finding of a fault away from what you are looking at.

@Crasher I assume you are the very same from VW forums, as you have replied on a thread regarding this fault and the person also reported -270C (might be because it doesn't exist on all model)

Maybe you can chime in with some insight as you have superior knowledge?

Regarding the exchange unit, that has been dropped. Yes I am the same Crasher as on the VW sites. That sensor maybe reading that value as it isn’t fitted, the cars VIN would help me check.

Hi everyone, thanks for all the further information, I have since gone underneath the car and inspected the egr motor and gears inside, they are in perfect condition with no signs of wear and the valve appears to move, I also did a egr test through vcds and no errors were reported. However the arm which is connected to the flap actuated by the vacuum solenoid was seized solid and not moving, I applied some wd40 and moved the arm back and fourth until it moved freely. So far this is the only issue I can find with it.

One common failure is the flap sticking, we did one on a 2012 T5 last week with the high output CFCA engine, the flap was stuck and the cooler blocked solid, on these the complete unit is £1127.95 and takes a full day to fit.

Sounds like you have nailed it, well done!

 

Regarding the after EGR temp sensor, I take all the VAG/VCDS (not sure who is to blame) units with a pinch of salt, they seem to flip between guage and absolute pressure on different parameters without specifying which, same with temperature & volume units etc, it shows 276°C but I would bet that they are actually using the Kelvin scale.

 

Positive and negative signs also seem to be random those they use for torsion value (cam timing) are definitely backwards.

 

So -270.6°c is probably +270.6°K or 3.6°C, which for this time of year is out even for a cold engine but given that the sensor is intended to be reading temps in the 500°c range, 873° Kelvin being out by 20°K equates to 2 percent or so and wont make a scrap of difference, it may need recalibrating, I have forgotten the phrase they use for that in regards to the DPF differential pressure sensor, offset I think.

Edited 11 September, 20223 yr by J.R.

Hi everyone,

 

I have now driven about 2000 miles since the fix and so far the car has not gone into limp mode again so it looks like the seized flap was the issue and may be something to check for anyone else who gets egr codes. I did however have the engine warning light come on, but it went off after a few restarts of the engine so will have to see if any codes are stored for that. Will give an update when I get time to do so.