EGR replacement and 16786/P0402, Egr excessive flow

   #1  

Electrician70

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VCDS Serial number
C?ID=259444
Hi all, I'm new to this forum and hope I make myself clear. We have a VW 1.6 BCB Golf that didn't start one morning. 1st Auto-Scan was

Code:
Saturday,07,November,2015,13:34:15:35874
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 15.7.1.0 (x64)
Data version: 20150904
www.Ross-Tech.com


VIN: WVWZZZ1JZ6W021995   License Plate: 


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))

Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75

          76

 

VIN: WVWZZZ1JZ6W021995   Mileage: 120750km-75030miles

-------------------------------------------------------------------------------

Address 01: Engine        Labels: Redir Fail!

   Part No: 036 906 034 DR

   Component:  MARELLI 4MV G      5957  

   Coding: 00031

   Shop #: WSC 01266  

   VCID: 65F83722FFEDE416CE-FFFE

   WVWZZZ1JZ6W021995     VWZ7Z0E3010344



2 Faults Found:

17961 - Barometric / Manifold Pressure Signals 

            P1553 - 35-10 - Implausible Correlation - Intermittent

17912 - Intake Air System 

            P1504 - 35-10 - Leak Detected - Intermittent

Readiness: 0010 0101



-------------------------------------------------------------------------------

Address 03: ABS Brakes        Labels: 1C0-907-37x-ABS.lbl

   Part No: 1C0 907 379 L

   Component: ABS FRONT MK60      0101  

   Coding: 0001025

   Shop #: WSC 01266 785 00200

   VCID: 335C997A51B94AA690-FFFE



1 Fault Found:

01314 - Engine Control Module 

            013 - Check DTC Memory - Intermittent



-------------------------------------------------------------------------------

Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl

   Part No: 3B1 907 044 C

   Component: CLIMATRONIC     C 2.0.0  

   Coding: 11000

   Shop #: WSC 01266  

   VCID: 21706332AB45C83672-FFFE



No fault code found.



-------------------------------------------------------------------------------

Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl

   Part No: 1C0 909 605 A

   Component: 27 AIRBAG VW51 01   0008  

   Coding: 12855

   Shop #: WSC 01266  

   VCID: 22726C3EAE43D32E6B-FFFE



No fault code found.



-------------------------------------------------------------------------------

Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl

   Part No: 1J5 920 826 A

   Component: KOMBI+WEGFAHRSP VDO V23  

   Coding: 05113

   Shop #: WSC 00000  

   VCID: 2C6E8206DC87155ED1-FFFE

   WVWZZZ1JZ6W021995     VWZ7Z0E3010344



No fault code found.



-------------------------------------------------------------------------------

Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl

   Part No: 6N0 909 901 

   Component: Gateway K<->CAN    0001  

   Coding: 00006

   Shop #: WSC 01266  

   VCID: 70D65676302F31BEAD-FFFE



No fault code found.



-------------------------------------------------------------------------------

Address 46: Central Conv.        Labels: 1C0-959-799.lbl

   Part No: 1C0 959 799 B

   Component: 1A Komfortgerát HLO 0004  

   Coding: 00259

   Shop #: WSC 01266  

   VCID: 365AA06E12CB5F8EB7-FFFE



   Subsystem 1 - Part No: 1C1959801A

   Component: 1A Tõrsteuer.FS KLO 0202  



   Subsystem 2 - Part No: 1C1959802A

   Component: 1A Tõrsteuer.BF KLO 0202  



   Subsystem 3 - Part No: 1C0959811A

   Component: 1A Tõrsteuer.HL KLO 0202  



   Subsystem 4 - Part No: 1C0959812A

   Component: 1A Tõrsteuer.HR KLO 0202  



No fault code found.



-------------------------------------------------------------------------------

Address 56: Radio        Labels: 1K0-035-1xx-56.lbl

   Part No SW: 6Q0 035 152 A    HW: 6Q0 035 152 A

   Component: Radio BVX       005 0004  

   Revision: 00005000    Serial number: VWZ1Z5E2997505

   Coding: 0040400

   Shop #: WSC 01266 785 00200

   VCID: 28667E16987F397E35-FFFE



No fault code found.



End-------------------------(Elapsed Time: 07:32)--------------------------


So cleared DTCs, cleaned the throttle body, replaced the EGR valve with a new valve, adapted both and those dtc's passed by. Car behaves normally now but lights up MIL and "emission workshop." 2nd Auto-Scan was

Code:
Log-ASG-295-WVWZZZ1JZ6W021995-121560km-75533mi.txt

Wednesday,02,December,2015,15:43:19:35874
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 8.1 x64
VCDS Version: 15.7.1.0 (x64)
Data version: 20150904
www.Ross-Tech.com


VIN: WVWZZZ1JZ6W021995   License Plate: *****Mileage: 121560km-75533mi   Repair Order: 



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
          76
 
VIN: WVWZZZ1JZ6W021995   Mileage: 121560km-75533miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: Redir Fail!
   Part No: 036 906 034 DR
   Component:  MARELLI 4MV G      5957  
   Coding: 00031
   Shop #: WSC 01266  
   VCID: 65F83722FFEDE416CE-FFFE
   WVWZZZ1JZ6W021995     VWZ7Z0E3010344

1 Fault Found:
16786 - EGR System 
            P0402 - 35-00 - Excessive Flow
Readiness: 1010 0101

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ABS.lbl
   Part No: 1C0 907 379 L
   Component: ABS FRONT MK60      0101  
   Coding: 0001025
   Shop #: WSC 01266 785 00200
   VCID: 335C997A51B94AA690-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl
   Part No: 3B1 907 044 C
   Component: CLIMATRONIC     C 2.0.0  
   Coding: 11000
   Shop #: WSC 01266  
   VCID: 21706332AB45C83672-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 A
   Component: 27 AIRBAG VW51 01   0008  
   Coding: 12855
   Shop #: WSC 01266  
   VCID: 22726C3EAE43D32E6B-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J5 920 826 A
   Component: KOMBI+WEGFAHRSP VDO V23  
   Coding: 05113
   Shop #: WSC 00000  
   VCID: 2C6E8206DC87155ED1-FFFE
   WVWZZZ1JZ6W021995     VWZ7Z0E3010344

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00006
   Shop #: WSC 01266  
   VCID: 70D65676302F31BEAD-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 B
   Component: 1A Komfortgerát HLO 0004  
   Coding: 00259
   Shop #: WSC 01266  
   VCID: 365AA06E12CB5F8EB7-FFFE

   Subsystem 1 - Part No: 1C1959801A
   Component: 1A Tõrsteuer.FS KLO 0202  

   Subsystem 2 - Part No: 1C1959802A
   Component: 1A Tõrsteuer.BF KLO 0202  

   Subsystem 3 - Part No: 1C0959811A
   Component: 1A Tõrsteuer.HL KLO 0202  

   Subsystem 4 - Part No: 1C0959812A
   Component: 1A Tõrsteuer.HR KLO 0202  

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
   Part No SW: 6Q0 035 152 A    HW: 6Q0 035 152 A
   Component: Radio BVX       005 0004  
   Revision: 00005000    Serial number: VWZ1Z5E2997505
   Coding: 0040400
   Shop #: WSC 01266 785 00200
   VCID: 28667E16987F397E35-FFFE

No fault code found.

End-------------------------(Elapsed Time: 07:30)------------------

We have read that replacing an EGR valve may require an ECU reset. Previously learned egr values has to be erased they say. So took the car to dealer's workshop and ordered an ECU reset. It didn't help. MIL lights up at the first engine braking.

Can You help reading this 3rd Auto-Scan? Is there any kind of ecu reset done at the workshop? What does mean differences in VCIDs and readiness in the Engine module? Thanks for help in advance!!

Code:
Sunday,13,December,2015,14:38:31:35874
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 8.1 x64
VCDS Version: 15.7.2.0 (x64)
Data version: 20151124
www.Ross-Tech.com


VIN: WVWZZZ1JZ6W021995   License Plate: *****
Mileage: 122030km-75825mi   Repair Order: version2



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
          76
 
VIN: WVWZZZ1JZ6W021995   Mileage: 122030km-75825miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: Redir Fail!
   Part No: 036 906 034 DR
   Component:  MARELLI 4MV G      5957  
   Coding: 00031
   Shop #: WSC 01266  
   VCID: 65F83722FFEDE416F8-FFFE
   WVWZZZ1JZ6W021995     VWZ7Z0E3010344

1 Fault Found:
16786 - EGR System 
            P0402 - 35-00 - Excessive Flow
Readiness: 1000 0100

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ABS.lbl
   Part No: 1C0 907 379 L
   Component: ABS FRONT MK60      0101  
   Coding: 0001025
   Shop #: WSC 01266 785 00200
   VCID: 335C997A51B94AA6A6-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl
   Part No: 3B1 907 044 C
   Component: CLIMATRONIC     C 2.0.0  
   Coding: 11000
   Shop #: WSC 01266  
   VCID: 21706332AB45C83644-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 A
   Component: 27 AIRBAG VW51 01   0008  
   Coding: 12855
   Shop #: WSC 01266  
   VCID: 22726C3EAE43D32E5D-FFFE

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J5 920 826 A
   Component: KOMBI+WEGFAHRSP VDO V23  
   Coding: 05113
   Shop #: WSC 00000  
   VCID: 2C6E8206DC87155EE7-FFFE
   WVWZZZ1JZ6W021995     VWZ7Z0E3010344

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            80-10 - Single-Wire Operation - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00006
   Shop #: WSC 01266  
   VCID: 70D65676302F31BE9B-FFFE

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            80-10 - Single-Wire Operation - Intermittent

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 B
   Component: 1A Komfortgerát HLO 0004  
   Coding: 00259
   Shop #: WSC 01266  
   VCID: 365AA06E12CB5F8E81-FFFE

   Subsystem 1 - Part No: 1C1959801A
   Component: 1A Tõrsteuer.FS KLO 0202  

   Subsystem 2 - Part No: 1C1959802A
   Component: 1A Tõrsteuer.BF KLO 0202  

   Subsystem 3 - Part No: 1C0959811A
   Component: 1A Tõrsteuer.HL KLO 0202  

   Subsystem 4 - Part No: 1C0959812A
   Component: 1A Tõrsteuer.HR KLO 0202  

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
   Part No SW: 6Q0 035 152 A    HW: 6Q0 035 152 A
   Component: Radio BVX       005 0004  
   Revision: 00005000    Serial number: VWZ1Z5E2997505
   Coding: 0040400
   Shop #: WSC 01266 785 00200
   VCID: 28667E16987F397E03-FFFE

No fault code found.

End-------------------------(Elapsed Time: 07:45)----------
 
   #2  

Uwe

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The EGR valve is by no means the only possible source of problems with the EGR system. Have you verified that the rest of the plumbing is free of leaks and not clogged?

-Uwe-
 
   #3  

Jack@European_Parts

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Location
Montgomery, NY, USA
VCDS Serial number
C?ID=57337
1 Fault Found:
16786 - EGR System
P0402 - 35-00 - Excessive Flow

First off great first post Thank you.......!:p

The EGR is connected to a solenoid switch ( N18 ) and this could be stuck open, hooked up wrong or leaking internally out its vent, or opening the EGR causing an air leak. Inspect it..........Make sure the TV cable is set correctly.....mechanically.

Seems like you fixed the result and not the cause of your issue.

http://wiki.ross-tech.com/wiki/index.php/16786/P0402/001026


16786/P0402/001026 - Exhaust Gas Recirculation (EGR): Excessive Flow [h=4]Possible Symptoms[/h]
  • Malfunction Indicator Light (MIL) ON
  • Reduced Exhaust Gas Recirculation (EGR)
  • Reduced Power Output/Engine running rough
  • Increased Emissions
[h=4]Possible Causes[/h]
  • Exhaust Gas Recirculation (EGR) Valve stuck open/leaking/faulty
  • Exhaust Gas Recirculation (EGR) System leaking/faulty
  • Wiring and/or Connector(s) from/to Exhaust Gas Recirculation (EGR) Valve faulty
[h=4]Possible Solutions[/h]
  • Check/Clean Exhaust Gas Recirculation (EGR) System
  • Check/Replace Exhaust Gas Recirculation (EGR) Valve
  • Check Wiring and/or Connector(s) from/to Exhaust Gas Recirculation (EGR) Valve
 
   #4  

Electrician70

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Messages
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Location
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Thanks for the replies, guys! Problem solved, new egr valve was faulty. Tried to find a dP measuremet somewhere until we found that there's a pressure measurement inside the new valve what was faulty.
 
   #5  

Jack@European_Parts

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Messages
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Location
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VCDS Serial number
C?ID=57337
Wow bad out of the box is becoming more and more common.........

Was this a genuine part?
 
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