EGR Valve Code

[tomasz]

The dealer took the car, held on to it for 3 days and just informed me that the code is intermittent and possibly indicating a failing electric motor of the egr valve. They are not willing to replace it nor look into the possible cause of why the valve is getting stuck intermittently till a permanent failure occurs.
So aggravating, I am supposed to drive this car now till it happens again. Who in a right mind would want to do that - if I go on a long trip and the valve fails again, the car goes into limp mode and is unusable.
Not sure how to reason with the dealer as to me, they should be looking into why/if there is a carbon buildup and they are not.

 

[SaVAGeSoot]

That means you erased the codes before you took it in.... because the scan you showed had a confirmed code and MIL in it.

 

[Crasher]

I love it when people do that, sort of “my mate cleared the codes before I brought it in” Then when you get into the car and turn it on you get “beeeep, refuel now” FFS!

 

[tomasz]

That means you erased the codes before you took it in.... because the scan you showed had a confirmed code and MIL in it.

Yes, I erased the original fault codes from Jan 23, which was as shown below, thinking that it was caused by (related to) the low voltage situation, tied to the weak battery which I replaced as the first course of action:

Tuesday,23,January,2024,14:36:33:41104
VCDS Version Release 23.11.0 (x64) Running on Windows 10 x64(Parallels)
www.Ross-Tech.com

                Address 01: Engine       Labels: 059-907-401-V2.clb
Control Module Part Number: 8K5 907 401 AC    HW: 4G0 907 401 E
  Component and/or Version: 3.0TDI FSA    H14 0008
           Software Coding: 2A2A4012053603050000
            Work Shop Code: WSC 11886 002 1048576
              ASAM Dataset: EV_ECM30TDI0118K5907401AC 002008 (AU48)
                       ROD: EV_ECM30TDI0118K5907401AC_002.rod
                      VCID: 71E96F35A0098A193C-8025
2 Faults Found:

31982 - EGR Valve (N18)
          P0403 00 [01100101] - Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 155984 km
                    Date: 2024.01.23
                    Time: 14:22:55

                    Engine RPM: 1820.50 /min
                    Normed load value: 54.5 %
                    Vehicle speed: 34 km/h
                    Coolant temperature: 14 °C
                    Intake air temperature: 10 °C
                    Ambient air pressure: 810 mbar
                    Voltage terminal 30: 13.560 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 496.6 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 27.19 %
                    EGR Solen.val.: actual value: 100.00 %
                    EGR valve: offset closed: 0.10 %
                    High press EGR actuator: actual unconditioned volt val: 796.6 mV
                    EGR valve: offset open: -0.10 %

37931 - EGR Valve (N18)
          P0403 00 [01100101] - Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 155984 km
                    Date: 2024.01.23
                    Time: 14:23:01

                    Engine RPM: 1888.50 /min
                    Normed load value: 56.5 %
                    Vehicle speed: 41 km/h
                    Coolant temperature: 15 °C
                    Intake air temperature: 10 °C
                    Ambient air pressure: 810 mbar
                    Voltage terminal 30: 13.800 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 455.0 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 100.00 %
                    EGR Solen.val.: actual value: 100.00 %
                    EGR valve: offset closed: 0.10 %
                    High press EGR actuator: actual unconditioned volt val: 796.6 mV
                    EGR valve: offset open: -0.10 %


Readiness: 0 0 0 1 1

The Q5 had some other curious codes in the system back then which were tripped by the bad battery situation. All codes were cleared and none came back after the battery issue got addressed with a battery replacement and a proper battery coding.


My wife drove the vehicle for a month and then the EGR fault came back on Feb 29 as shown below, and I have not cleared this one, I delivered the car to the dealer this way.

Address 01: Engine (J623-CPNB)       Labels:. 059-907-401-V2.clb
   Part No SW: 8K5 907 401 AC    HW: 4G0 907 401 E
   Component: 3.0TDI FSA    H14 0008
   Revision: 58H14---    CVN: E29A4E35C19C777138D3FF8238D3FF820E1FC39E
   Coding: 2A2A4012053603050000
   Shop #: WSC 11886 002 1048576
   ASAM Dataset: EV_ECM30TDI0118K5907401AC 002008
   ROD: EV_ECM30TDI0118K5907401AC_002.rod
   VCID: 71E96F35A0098A193C-8025
   VINID: 9D10539915A02174400C624800B38EEB44

1 Fault Found:
31982 - EGR Valve (N18)
          P0403 00 [11101101] - Malfunction
          MIL ON - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 158005 km
                    Date: 2024.02.29
                    Time: 13:39:02

                    Engine RPM: 762.50 /min
                    Normed load value: 43.5 %
                    Vehicle speed: 4 km/h
                    Coolant temperature: 53 °C
                    Intake air temperature: 20 °C
                    Ambient air pressure: 820 mbar
                    Voltage terminal 30: 13.100 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 624.4 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 96.88 %
                    EGR Solen.val.: actual value: 99.87 %
                    EGR valve: offset closed: 0.82 %
                    High press EGR actuator: actual unconditioned volt val: 776.8 mV
                    EGR valve: offset open: -0.82 %

Readiness: 1 1 0 1 0

One would hope that if the dealer's procedure is to trigger/observe the code twice, I should be able to provide documentation from VCDS documenting that it has happened for the second time already and have them start the repairs, no? (I did save the VCDS report from Jan 23rd).

The other thing is, can these codes be thrown by otherwise good valve/motor controller which would operate properly if the system was cleaned up from the carbon buildup? The local shops seem to clean the system from carbon as part of the advised remedy. Not sure why audi dealer choses not to and tries talking us into driving this unreliable vehicle…

Am I mistaken here or should I be able to talk them into cleaning up the carbon buildup based on the history of the faults?

 

[SaVAGeSoot]

You're dreaming.
The dealer will only do something if you roll in there with a CEL\MIL on.
They won't care about any historical scans or data you or someone else has.
They will also only deal with carbon buildup if they find it when troubleshooting whatever has caused the MIL.... so let's say, you have a intake flap code, they take it apart and it's all full of carbon buildup.... they remove that to replace it, and the intake manifold is also blocked with carbon....
The dealer will do everything in their power to get out past the AEM coverage expiry, at which point they will start replacing everything at crazy costs.... they don't make any money on warranty covered things.

 

[tomasz]

Well, and that is what I believe they act like but the CEL was on when I turned the vehicle in and the faults were in the system, they are just saying they need to trigger them again ... why? As the car is unreliable to drive.
grrr

 

[SaVAGeSoot]

they are just saying they need to trigger them again ... why?

I don't know... I wasn't there, and did you have an opportunity to discuss any of this.
Did you produce the warranty booklet?
Did you call head office to ask where in the booklet it says such things?
Anyone can tell you anything... it's up to you if you accept it or challenge it or whatever.....

 

[tomasz]

Well, could not talk Audi into allowing the dealer to admit more evidence for a repeating fault to start the repair. At least they promised to consider reimbursing of the towing cost, should we get stranded due to this problem again. Driving the car and will see what happens.

 

[tomasz]

The faults are back, heading to the dealer for what I hope will be warranty based repairs:

2 Faults Found:

31982 - EGR Valve (N18)
          P0403 00 [11101101] - Malfunction
          MIL ON - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 159654 km
                    Date: 2024.04.22
                    Time: 08:56:19

                    Engine RPM: 2206.00 /min
                    Normed load value: 99.6 %
                    Vehicle speed: 52 km/h
                    Coolant temperature: 54 °C
                    Intake air temperature: 19 °C
                    Ambient air pressure: 820 mbar
                    Voltage terminal 30: 14.380 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 427.4 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 100.00 %
                    EGR Solen.val.: actual value: 99.96 %
                    EGR valve: offset closed: 0.43 %
                    High press EGR actuator: actual unconditioned volt val: 786.8 mV
                    EGR valve: offset open: -0.43 %

37931 - EGR Valve (N18)
          P0403 00 [11101101] - Malfunction
          MIL ON - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 159651 km
                    Date: 2024.04.22
                    Time: 08:52:31

                    Engine RPM: 889.50 /min
                    Normed load value: 60.4 %
                    Vehicle speed: 6 km/h
                    Coolant temperature: 23 °C
                    Intake air temperature: 17 °C
                    Ambient air pressure: 810 mbar
                    Voltage terminal 30: 12.940 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 360.3 mg/stroke
                    EGR Vacuum Regulator Solen.val.: activation: 6.99 %
                    EGR Solen.val.: actual value: 99.82 %
                    EGR valve: offset closed: 0.43 %
                    High press EGR actuator: actual unconditioned volt val: 791.6 mV
                    EGR valve: offset open: -0.43 %


Readiness: 1 2 0 1 0

 

[SaVAGeSoot]

Yup, those will be covered.

 

[tomasz]

Audi is picking up the repair cost indeed but the dealer is telling me now that even though they have replaced the EGR module and the valve, they only cleaned up the carbon buildup in the mount point and not the entire manifold, despite noticing significant buildup in the system.
Would this be acceptable? Wouldn't a standard procedure be to clean it all up once they are there?

 

[SaVAGeSoot]

Would this be acceptable?

You're asking us if YOU accepted this "solution"?
Cleaning carbon buildup off that type of intake is nearly impossible and very difficult.
Unless corporate approved a replacement manifold, the dealership would lose their shirt cleaning it, so they would never take that approach.
The dealership is only going to do the minimal amount of fixing that will make your codes\MIL to go away..... nothing more.