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After over a week with the new Pierburg exhaust gas recirc valve in place. No more associated EGR faults appearing. Briefly monitoring VCDS measuring block group 123, field 4 (which is the exhaust gas recirc valve position signal) we have noted that this value now goes from 0.76 to 3.7 V...

P.S. Our new Pierburg valve opened a max of approx ONLY 1.5mm during a VCDS Output test. The max possible valve lift measured with a DTI was 5.36mm when the Pierburg valve was opened manually via the gears (plastic cover removed) and a lift of 5.36mm is also achieved when putting 12V directly...

Fitted a Pierburg aftermarket EGR valve from Eurocarparts, performed a basic setting and crossed fingers. Not convinced that the voltage in field 4 of Engine group 123 (which I believe is 0.5 - 5V EGR valve position feedback) comes anywhere close to matching the expected value based on the EGR...

Thanks @Crasher - much appreciated! Still think we have an ECU issue and also it is clear that fault P0403 (EGR malfunction) which is what we have, is listed on the Bosch website as a typical fault for our particular ECU. As far as I can see on VCDS there are 3 setup operations related to the...

We would be extremely grateful if anyone could confirm for definite if our EGR valve is supposed to open fully during a VCDS Output test. We are working on the assumption that it should. Our EGR valve is driven by a pulse wave modulated 12V motor. It only opens very slightly during a VCDS...

We have tried injecting 12V at ECU plug pins T60/19 and T60/04 with ECU plugs and battery disconnected. The EGR valve opens fully - which is a good test of the loom. If our EGR valve (driven by a 12V PWM motor) is supposed to open fully during a VCDS Output test then quite clearly the ECU is not...

Just received our Bosch EDC17CP14 ECU back from ACtronics. They did not find anything wrong, though apparently they did not load test the 12V output to the EGR valve as they “did not have a loom or EGR valve” I’m not sure why they could not use alternatives. Will continue with a few more tests...

The second specialist company now has the ECU, Keys and Instrument Cluster. Should get some feedback from them this week...

Absolutely agree!!!

Hi @Robski, I agree with you to a significant degree. To me, continuity testing is only an indicator. I prefer testing live and looking for volt drops where there shouldn't be any - wherever this is feasible.

It is almost certain that our EGR valve problem is an ECU issue. VCDS Engine Group 123, field 4 went from 0.7V to 5.0V when the EGR valve was manually positioned at closed and full open respectively so feedback looks good. Pin to pin wiring integrity is good for all 5 wires connected to the EGR...

Hi @Badea_Cristian, We have the same issue when testing with a new EGR valve and circumventing the EGR is not on our list of preferred solutions.

Thanks @stylers, We have good continuity from all wires on the EGR valve plug back to the Engine ECU pins and no continuity to ground on any of them when measured on a multimeter Megohm scale. According to the drawing, T6/3 on the EGR valve plug should be grounded and is not. We tried...

I believe that Bosch in Germany currently have a turn-around time of around 3 weeks and we can not be certain what the end result will be. They will also not deal with "end users" so we would presumably have to do via a specialist. A new ECU supplied, fitted and programmed is not far off £2000...

Further update, the ECU company we chose was unable to complete tests of our particular Engine ECU and is returning it so we will have to find another way forward.

Thanks @Crasher, That at least gives us a clue of where earth 85 might be - and narrows down where to look. Our EGR valve T6/3 DEFINITELY has no continuity to earth. The CBDC Current Flow Diagram shows that T6/3 should have continuity to earth. We did have continuity from T6/3 to T60/53. Also...

Weather permitting will give it a try tomorrow. It's around 23:20hrs in the UK now. Will be brilliant if it works and given that the car is not far off 13 years old we may decide that we can make this a "permanent" repair if it works and access to the point of failure is likely to be awkward. We...

Hi @Crasher, Current thinking is that we could introduce a temporary earth connection at T6/3 and see if this allows the EGR valve to operate. Any feedback on that idea appreciated. I'm assuming that the ECU may not give the appropriate pulse width modulated signal to the motor unless it has an...

Hi @Crasher, Finally put my hands on the exact circuit flow diagram for our B6 Passat. I hadn’t realised that the wiring PDF document contained a number of different current flow diagrams depending on engine code. Our engine code is CBDC. Before committing to use a “charlatan” and now with the...

Hi @Crasher, As I believe you may have hinted at, I would have expected other faults to register on VCDS if any other actuators/sensors that share a feed with the EGR valve were faulty. As all continuity tests and tests to earth were good (even though I did not disconnect linked devices), it’s...