A friend has a UK B6 VW Passat (manufactured 2009). Recently it has had an engine warning light come up on the dash. We connected up my VCDS and found that there was an EGR valve fault.
The fault indicated on VCDS was:-
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction
I have attached an auto-scan taken after the engine fault light came on:-
We removed the EGR valve and cleaned it in an ultrasonic bath taking care to keep the electrics clear of the water. After plugging the valve in electrically we carried out a VCDS Output test on it. There was a high pitched buzzing sound each time the valve tried to open, but the valve barely moved (possibly only a fraction of a mm).
We removed the plastic gear case cover and operated the gears by hand. The valve lifted freely over its full stroke (at least an estimated 6mm) against firm spring pressure. We put the plastic gearcase cover back on and carried out the VCDS Output test again. Still the same. The valve barely moved.
We then carried out a Basic Setting on Group 123 (as indicated by the menu system for EGR valve basic setting). It appeared to attempt a calibration before Basic Setting automatically turned off. Again the valve barely moved.
The four fields in the Basic Settings window (Group 123) showed the following on completion of the calibration activity:- 0.0%, 00000100, 00000010, 0.684V
We noted that there is an EGR valve RESET function in the Adaptations menu. We did not activate this as we were uncertain of its purpose and whether its use would be appropriate.
Finally, we re-installed the EGR valve and cleared DTC’s. There are currently no engine faults showing on the auto-scan. We believe it is most likely that the EGR fault will soon re-appear.
The fault indicated on VCDS was:-
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction
I have attached an auto-scan taken after the engine fault light came on:-
Code:
Sunday,17,October,2021,16:20:30:27553
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 21.9.0.2 (x64) HEX-V2 CB: 0.4555.4
Data version: 20210903 DS330.0
www.Ross-Tech.com
VIN: WVWZZZ3CZ9E098608 License Plate:
Mileage: 309650km-192407mi Repair Order:
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
Chassis Type: 3C-VW46 (3C0)
Scan: 01 03 08 09 15 16 17 19 25 37 42 44 46 52 53 56 6C
VIN: WVWZZZ3CZ9E098608 Mileage: 309650km-192407miles
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
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: Malfunction 0010
37-Navigation -- Status: Malfunction 0010
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: Malfunction 0010
56-Radio -- Status: Malfunction 0010
6C-Back-up Cam. -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (CBD) Labels: 03L-906-022-CBA.clb
Part No SW: 03L 906 022 BT HW: 03L 907 309
Component: R4 2,0L EDC 0000SG 6214
Revision: 13H01--- Serial number: VWZCZ000000000
Coding: 0000071
Shop #: WSC 00363 210 85044
VCID: 78AAE15AFED5F1DB9F1-802C
VINID: 9E69EAAAA0D3A8954024818020F8E835AA
2 Faults Found:
001299 - Incorrect Immobilizer Key
P0513 - 000 - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 309476 km
Time Indication: 0
Date: 2016.03.09
Time: 21:26:36
Freeze Frame:
RPM: 989 /min
Speed: 0.0 km/h
Voltage: 11.63 V
Absolute Pres.: 1009.8 mbar
Absolute Pres.: 969.0 mbar
Temperature: 18.9∞C
Temperature: 18.9∞C
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction
Freeze Frame:
Fault Status: 01100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 309648 km
Time Indication: 0
Date: 2016.03.09
Time: 07:37:04
Freeze Frame:
RPM: 1702 /min
Speed: 42.0 km/h
Load: 0.0 %
Load: 16.9 %
Lambda: 27.6 %
Mass Air / Rev.: 275.0 mg/str
Temperature: 81.0∞C
Readiness: 0 0 0 0 0
-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels:. 3C0-614-109-C4.clb
Part No SW: 3C0 614 109 T HW: 3C0 614 109 T
Component: J104 C4 440 V2 0013
Revision: --025--- Serial number: 00000786438999
Coding: 0001286
Shop #: WSC 05311 000 00000
VCID: 2F381A064B1BF6630EB-807A
No fault code found.
-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 1K0-820-047.lbl
Part No SW: 1K0 820 047 JD HW: 1K0 820 047 JD
Component: Climatic PQ35 143 1313
Revision: 00143033 Serial number: 00000000000000
Shop #: WSC 00000 000 00000
VCID: 6FB8DA068B9BB6634EB-803A
No fault code found.
-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 3C0-937-049-30-M.lbl
Part No SW: 3C8 937 049 D HW: 3C8 937 049 D
Component: Bordnetz-SG H54 2602
Revision: 00H54000 Serial number: 00000009125181
Coding: 00880F0700041A00470A00000F000000000859435C000120000000000000
Shop #: WSC 05124 000 00000
VCID: 323E13725829DB8B615-8066
Subsystem 1 - Part No: 3C2 955 119 B Labels: 1KX-955-119.CLB
Component: Wischer 201108 022 0601
Coding: 00046997
Shop #: WSC 05124
No fault code found.
-------------------------------------------------------------------------------
Address 15: Airbags Labels: 5N0-959-655.lbl
Part No SW: 5N0 959 655 A HW: 5N0 959 655 A
Component: J234__00Q VW10 HI 1815
Revision: 19013000 Serial number: 0039DPQZAV1O
Coding: 0012369
Shop #: WSC 05311 000 00000
VCID: 3B203E568F631AC3B23-806E
Subsystem 1 - Serial number: 6333FTS691633018
Subsystem 2 - Serial number: 6343FTS635553408
Subsystem 3 - Serial number: 6353ETS6R6PVVVNR
Subsystem 4 - Serial number: 6363ETS6RQ45V5KJ
Subsystem 5 - Serial number: 00000000000000000
Subsystem 6 - Serial number: 00000000000000000
No fault code found.
-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 3C0-953-549-SW25.lbl
Part No SW: 3C0 953 549 AT HW: 3C0 953 549 AT
Component: J0527 0030
Revision: 00034000 Serial number: 3C9953507CE
Coding: 0000004
Shop #: WSC 05314 000 00000
VCID: 7EA6F742DCF1CFEBD5D-802A
No fault code found.
-------------------------------------------------------------------------------
Address 17: Instruments (J285) Labels:| 3C8-920-xxx-17.clb-SRI1
Part No SW: 3C0 920 971 R HW: 3C0 920 971 R
Component: KOMBI H04 0107
Serial number: 00000000000000
Coding: 460F00
Shop #: WSC 05314 115 00000
ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04040
ROD: EV_Kombi_UDS_VDD_RM09_004_VW46.rod
VCID: 3432156AAEBDD5BB739-8060
No fault code found.
-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:. 3C0-907-530-V3.clb
Part No SW: 3C0 907 530 L HW: 3C0 907 951
Component: J533__Gateway H13 0152
Revision: H13 Serial number: 3300P08C0804AD
Coding: F9801F06404202002003
Shop #: WSC 05314 000 00000
VCID: 2A0E0B1270F9934BD95-807E
No fault code found.
-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 3C0-959-433-25.clb
Part No SW: 3C0 959 433 AQ HW: 3C0 959 433 AQ
Component: IMMO 044 0383
Revision: 00044000 Serial number: VWZCZ000000000
Shop #: WSC 131071 1023 2097151
VCID: 79ACE45EC5DFE8D3E0F-802C
Subsystem 1 - Part No: 3C0 905 861 G
Component: ELV 027 0380
3C0905861G ELV 027 0380
1 Fault Found:
02861 - Electronic Steering Column Lock Check Sum Error
008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 4
Fault Frequency: 2
Reset counter: 182
Mileage: 308037 km
Time Indication: 0
Date: 2016.03.09
Time: 21:08:50
-------------------------------------------------------------------------------
Address 37: Navigation (J0506) Labels:. 1T0-035-680.clb
Part No SW: 1T0 035 680 L HW: 1T0 035 680 BX
Component: RNS-MID H03 5238
Revision: AB001001 Serial number: VWZ6Z7H6306026
Coding: 00010400000000000000
Shop #: WSC 12345 123 12345
VCID: 37282266BF4B3EA356B-8062
Subsystem 1 - Part No: 1T0 919 859 B
Component: EU West V16 8536
1 Fault Found:
00823 - Line-Output; Front Left
007 - Short to Ground
Freeze Frame:
Fault Status: 01100111
Fault Priority: 5
Fault Frequency: 254
Reset counter: 151
Mileage: 293872 km
Time Indication: 0
-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels:. 1K0-959-701-MIN3.clb
Part No SW: 1K0 959 701 AC HW: 1K0 959 793 N
Component: J386 TUER-SG FT 1518
Revision: 72009005 Serial number: 00000628989110
Coding: 0000565
Shop #: WSC 05311 000 00000
VCID: 6FB8DA068B9BB6634EB-803A
No fault code found.
-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1K0-909-14x-GEN3.clb
Part No: 1K0 909 144 E
Component: EPS_ZFLS Kl. 195 2501
Revision: 00H15000
Shop #: WSC 02069 000 90108
VCID: 2C020D0A7A0D8D7B2B9-8078
1 Fault Found:
00750 - Warning Lamp
013 - Check DTC Memory - Intermittent
Freeze Frame:
Fault Status: 00101101
Fault Priority: 2
Fault Frequency: 3
Reset counter: 201
Mileage: 302237 km
Time Indication: 0
Date: 2016.03.09
Time: 06:07:42
Freeze Frame:
Voltage: 11.38 V
DD
Temperature: 8.0∞C
RPM: 1229 /min
Speed: 0.0 km/h
Speed: 0.0 km/h
Count: 0
-------------------------------------------------------------------------------
Address 46: Central Conv. Labels:. 3C0-959-433-46.clb
Part No SW: 3C0 959 433 AQ HW: 3C0 959 433 AQ
Component: KSG PQ46 ELV 044 0612
Revision: 00044000 Serial number: VWZCZ000000000
Coding: 0191020851030E763004941570085BCE103C01
Shop #: WSC 05311 000 00000
VCID: 79ACE45EC5DFE8D3E0F-802C
Subsystem 1 - Component: Sounder No Answer
Subsystem 2 - Part No: 3C0 951 171 C
Component: Neigungssensor 004 0611
Subsystem 3 - Part No: 3C0 951 171 C
Component: Innenraumueberw.004 0611
1 Fault Found:
01134 - Alarm Horn (H12)
004 - No Signal/Communication
Freeze Frame:
Fault Status: 01100100
Fault Priority: 4
Fault Frequency: 14
Reset counter: 168
Mileage: 302236 km
Time Indication: 0
Date: 2016.03.09
Time: 09:27:45
-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels:. 1K0-959-702-MIN3.clb
Part No SW: 1K0 959 702 AC HW: 1K0 959 792 N
Component: J387 TUER-SG BT 1518
Revision: 72009005 Serial number: 00000513489111
Coding: 0000564
Shop #: WSC 05311 000 00000
VCID: 70BAD97A96A5A99B571-8024
No fault code found.
-------------------------------------------------------------------------------
Address 53: Parking Brake Labels: 5N0-907-801.clb
Part No SW: 3C8 907 801 A HW: 3C8 907 801 A
Component: J540 EPB3 VW-10498 0003
Revision: 009 Serial number: 00000000217648
Coding: 0000057
Shop #: WSC 05311 000 00000
VCID: 280AF11A6EF5A15BCF1-807C
1 Fault Found:
03200 - Switch for Electric Parking Brake (E538)
012 - Electrical Fault in Circuit - Intermittent
Freeze Frame:
Fault Status: 00101100
Fault Priority: 2
Fault Frequency: 12
Reset counter: 171
Mileage: 307046 km
Time Indication: 0
Date: 2016.03.09
Time: 06:21:09
Freeze Frame:
Voltage: 9.70 V
Count: 93
Speed: 0.0 km/h
Hex Value: 0x12E1
Hex Value: 0x0001
Hex Value: 0x1010
-------------------------------------------------------------------------------
Address 56: Radio (J0506) Labels:. 1T0-035-680.clb
Part No SW: 1T0 035 680 L HW: 1T0 035 680 BX
Component: RNS-MID H03 5238
Revision: AB001001 Serial number: VWZ6Z7H6306026
Coding: 00010400000000000000
Shop #: WSC 12345 123 12345
VCID: 37282266BF4B3EA356B-8062
Subsystem 1 - Part No: 1T0 919 859 B
Component: EU West V16 8536
1 Fault Found:
00823 - Line-Output; Front Left
007 - Short to Ground
Freeze Frame:
Fault Status: 01100111
Fault Priority: 5
Fault Frequency: 254
Reset counter: 151
Mileage: 293872 km
Time Indication: 0
-------------------------------------------------------------------------------
Address 6C: Back-up Cam. Labels: 5N0-907-441.clb
Part No SW: 3C0 907 441 HW: 3C0 907 441
Component: J772__Rearview 0042
Revision: 00H05000 Serial number: PA8 J8X0064
Coding: 0000007
Shop #: WSC 05311 000 00000
VCID: 5F98AAC67B3B26E3FEB-800A
No fault code found.
End----(Elapsed Time: 01:09, VBatt start/end: 11.7V/11.7V. VIgn 11.7V)-----
We removed the EGR valve and cleaned it in an ultrasonic bath taking care to keep the electrics clear of the water. After plugging the valve in electrically we carried out a VCDS Output test on it. There was a high pitched buzzing sound each time the valve tried to open, but the valve barely moved (possibly only a fraction of a mm).
We removed the plastic gear case cover and operated the gears by hand. The valve lifted freely over its full stroke (at least an estimated 6mm) against firm spring pressure. We put the plastic gearcase cover back on and carried out the VCDS Output test again. Still the same. The valve barely moved.
We then carried out a Basic Setting on Group 123 (as indicated by the menu system for EGR valve basic setting). It appeared to attempt a calibration before Basic Setting automatically turned off. Again the valve barely moved.
The four fields in the Basic Settings window (Group 123) showed the following on completion of the calibration activity:- 0.0%, 00000100, 00000010, 0.684V
We noted that there is an EGR valve RESET function in the Adaptations menu. We did not activate this as we were uncertain of its purpose and whether its use would be appropriate.
Finally, we re-installed the EGR valve and cleared DTC’s. There are currently no engine faults showing on the auto-scan. We believe it is most likely that the EGR fault will soon re-appear.
- Should the EGR valve do a full stroke when tested using the VCDS Output test? We assume that it should.
- Any suggestions as to what we can do next to resolve our issue with the EGR valve?