Audi A4 B8 2.0 TDI (177hp) – P0401 EGR insufficient flow

   #1  

Byte

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VCDS Serial number
C?ID=491001
Hi everyone,

I’m having an ongoing issue with my Audi A4 2.0 TDI 177hp (2014, currently 347,000 km) and would really appreciate some input.
I’ll try to keep this as clear and structured as possible:


Background (around 320,000 km):
About 1.5 years ago, I noticed a strange smell after driving (not oil-related) and more smoke than usual from the exhaust (visible in the rear-view mirror).
The car was still driving perfectly fine: full power, normal fuel consumption, no warning lights.
I performed a VCDS scan (see log 1) and it showed:
1 Fault Found:
4807 - EGR System
P0401 00 [01100000] - Insufficient Flow
Intermittent - Not Confirmed - Tested Since Memory Clear

No check engine light at this point, so I continued driving.

Around 335,000 km (APK / emissions test):
During the Dutch APK (MOT/emissions test), the car failed due to high particle emissions.
The mechanic suspected the EGR and replaced it.
After replacing the EGR:
  • The smoke and bad smell disappeared
  • The car passed the emissions test (although I’m not 100% sure if it actually passed, or if the mechanic just felt bad for me after he replaced the EGR, so he just faked the test)
Shortly after (a few days later):
The check engine light (CEL) came on.
I checked it with VCDS, now it showed this (see log 2):
1 Fault Found:
4807 - EGR System
P0401 00 [11101000] - Insufficient Flow
MIL ON - Intermittent - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Priority: 2
Fault Frequency: 2
Mileage: 335473 km
Date: 2025.11.04
Time: 17:25:17

Engine RPM: 1398.00 /min
Normed load value: 32.9 %
Vehicle speed: 38 km/h
Coolant temperature: 73 C
Intake air temperature: 21 C
Ambient air pressure: 1010 mbar
Voltage terminal 30: 14.680 V
Unlearning counter according OBD: 40
Air mass: specified value: 280.0 mg/stroke
Air mass: actual value (mg/stroke): 432.1 mg/stroke
EGR Solen.val.: actual value: 16.15 %
Throttle valve adapter: actual value: 25.37 %
Charge air pressure: specified value: 1068 hPa
Charge air pressure: actual value: 1161 hPa
Mean injection quantity: 10.90 mg/stroke

What has been done since:

  • Mechanic suspected an air leak -> he performed some kind of smoke test -> A small component (unsure which one) was replaced (~€100)
  • CEL returned within 2 days
Since then:
  • I’ve driven about 12.000 km
  • The CEL is on about 80% of the time (sometimes disappears temporarily)
  • The car still drives perfectly:
    • No power loss
    • No abnormal fuel consumption
    • No noticeable drivability issues

Summary:
  • 320k km: smell + smoke + intermittent EGR fault, no CEL
  • 335k km: fails emissions test → EGR replaced → smell and smoke symptoms gone
  • Shortly after: EGR fault returns, this time the check engine light turns on
  • Air leak checked and repaired → no fix
  • Now at 347k km: drives fine, but CEL is on for most of the time.

My thoughts / questions:
I’m considering the DPF as a possible cause, but I’d like to rule out other things first due to the cost.

Questions:
  • Does the EGR needs to be programmed to the car, after it has been installed? I asked the mechanic, and according to him it's not required.
  • What would be the logical diagnostic steps from here?
  • Could this still be a faulty (aftermarket) EGR valve, even though it’s new? How to check?
Any advice or similar experiences would be greatly appreciated.


Thanks in advance!



Log 1 (320.000 km)
Code:
Tuesday,04,February,2025,20:06:00:35772
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 11 x64
VCDS Version: 24.7.1.0 (x64)  HEX-V2 CB: 0.4643.4
Data version: 20240919 DS356.3
www.Ross-Tech.com


VIN: WAUZZZ8K2EA119576 
Mileage: 320460km-199124mi   Repair Order:



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


Chassis Type: 8K-AU48 (8R0)
Scan: 01 02 03 05 08 09 13 15 16 17 18 19 42 44 46 52 53 56 5C 5F
          62 69 72

VIN: WAUZZZ8K2EA119576   Mileage: 320460km-199124miles

01-Engine -- Status: OK 0000
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
13-Auto Dist. Reg -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
18-Aux. Heat -- Status: Malfunction 0010
19-CAN Gateway -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: OK 0000
56-Radio -- Status: OK 0000
5C-Lane Maintain. -- Status: OK 0000
5F-Information Electr. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
69-Trailer -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CGLC)       Labels:. 03L-906-018-CGL.clb
   Part No SW: 03L 906 018 JJ    HW: 03L 906 018 JL
   Component: R4 2.0l TDI   H25 9978
   Revision: 45H25---    CVN: E2F673E6
   Coding: 1203401A245401080000
   Shop #: WSC 00649 002 1048576
   ASAM Dataset: EV_ECM20TDI01103L906018JJ 003010
   ROD: EV_ECM20TDI01103L906018JJ.rod
   VCID: 7BA20B4B736DDB120A9-802E
   VINID: 9D196AAAA21B09544104914718ECDEE6F3

1 Fault Found:
4807 - EGR System
          P0401 00 [01100000] - Insufficient Flow
          Intermittent - Not Confirmed - Tested Since Memory Clear

Readiness: 0 0 0 0 0

-------------------------------------------------------------------------------
Address 02: Auto Trans (J217)       Labels:| 0AW-927-156.clb
   Part No SW: 8K5 927 155 L    HW: 0AW 927 156 K
   Component: 0AW_20TDI_RdW H06 0004
   Revision: --H06---    Serial number: 0000001226 CVN: 0000FFE2
   Coding: 000002
   Shop #: WSC 06325 000 00000
   ASAM Dataset: EV_TCMVL381 A02433
   ROD: EV_TCMVL381.rod
   VCID: 41DEB9A3510171C2105-8014

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 8K0-907-379-V2.clb
   Part No SW: 8K0 907 379 CN    HW: 8K0 907 379 CN
   Component: ESP8 front    H09 0020
   Revision: --------    Serial number: --------------
   Coding: 179DCC01
   Shop #: WSC 06325 000 00000
   VCID: 074A67BB3F258FF21E1-8052

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. (J393)       Labels:. 8K0-907-064-05.clb
   Part No SW: 8K0 907 064 JD    HW: 8K0 907 064 JD
   Component: BCM2 2.0      H14 0650
   Revision: 00002001  
   Coding: 01A24000000000000000
   Shop #: WSC 06325 000 00000
   VCID: 7BA20B4B73EDDB120A9-802E

   Subsystem 1 - Part No SW: 8K0 959 754 H    HW: 8K0 959 754 H
   Component: FBSAUDIB8 IDG  H71 0083
   Serial number: 0514000021869019  

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:. 8Kx-820-043-3Z.clb
   Part No SW: 8K1 820 043 AJ    HW: 8K1 820 043 AJ
   Component: KLIMA 3 ZONEN H04 0123
   Revision: C1000000    Serial number: 01080220141186
   Coding: 342800A000
   Shop #: WSC 06325 000 00000
   VCID: 70B82C672AABA84AAFB-8024

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 8K0-907-063.clb
   Part No SW: 8K0 907 063 DH    HW: 8K0 907 063 DH
   Component: BCM1 1.0      H16 0103
   Revision: 08016001    Serial number: 00000061963802
   Coding: 260000108034AFC00081400300001D0D0F1C670826090201000008004401020100000024000000
   Shop #: WSC 06325 000 00000
   VCID: 78A8144742DBF00A67B-802C

   Subsystem 1 - Part No SW: 8K1 955 119 B    HW: 8K1 955 119 B  Labels: 1KX-955-119.CLB
   Component: MITSUBA200114  H18 0461
   Serial number: 1401150707796      
   Coding: 004577

   Subsystem 2 - Part No SW: 8U0 955 559 B    HW: 8U0 955 559 B  Labels: 8U0-955-559.CLB
   Component: G397_RLFS  H06 0002
   Serial number: 22252182          
   Coding: 02005D

   Subsystem 3 - Part No SW: 8K0 941 531 AS    HW: 8K0 941 531 AS
   Component: E1 - LDS  H03 0031
   Serial number: 00000000000802140704

   Subsystem 4 - Part No SW: 4H0 907 658     HW: 4H0 907 658
   Component: AQ_Hum_Sensor  H03 0003
   Serial number: 6E380117000000000001

No fault code found.

-------------------------------------------------------------------------------
Address 13: Auto Dist. Reg (J428)       Labels: None
   Part No SW: 8K0 907 561 B    HW: 8K0 907 561 B
   Component: ACC3          H11 0100
   Serial number: 00000000000000
   Coding: 00F2D1
   Shop #: WSC 06325 000 00000
   VCID: 313EE963E121E142E05-8064

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 8K0-959-655.clb
   Part No SW: 8K0 959 655 N    HW: 8K0 959 655 N
   Component: AirbagVW-AU10 H47 0610
   Serial number: 003KFDB4CD7C   Dataset Number: 8K0909602Q  0001
   Coding: 30524435363030303030554A304C384B3053
   Shop #: WSC 33640 001 1048576
   ASAM Dataset: EV_AirbaECUVWAUDI010 003010
   ROD: EV_AirbaECUVWAUDI010_003_AU48.rod
   VCID: 48C8A487723B408AD7B-801C

   Crash sensor for side airbag: driver side:
   Serial number: 6334MSME433B7A69Q

   Front Passenger's Side Airbag Crash Sensor:
   Serial number: 6344MSME422C407EJ

   Rear Side Airbag Crash Sensor (on driver's side):
   Serial number: 6352QSME46402868F

   Passenger side rear thorax airbag crash sensor:
   Serial number: 6362QSME0A42585AM

   Crash sensor for front airbag: driver side:
   Serial number: 63732SME343D09660

   Crash sensor for front airbag: front passenger side:
   Serial number: 63832SME723C19641

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:. 8K0-953-568.clb
   Part No SW: 8K0 953 568 M    HW: 8K0 953 568 M
   Component: Lenks.Modul   H04 0005
   Revision: --------    Serial number: 90372NBA001CT
   Coding: 0000DF
   Shop #: WSC 06325 000 00000
   VCID: 44D0B0B74E9364EA3B3-8010

   Component: E221 - MFL  H03 0004

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:. 8T0-920-xxx-17.clb
   Part No SW: 8K0 920 932 A    HW: 8K0 920 932 A
   Component: KOMBIINSTR.   H35 0564
   Revision: 00200000    Serial number: ZCH53GD2F    
   Coding: 13E6100047010008000000
   Shop #: WSC 06325 000 00000
   VCID: 2D06F513FD1985A2C4D-8078

No fault code found.

-------------------------------------------------------------------------------
Address 18: Aux. Heat (J364)       Labels:. 8R0-265-105.clb
   Part No SW: 4H0 265 105 G    HW: 4H0 265 105 G
   Component: Standheizung  H24 0260
   Revision: 66006006    Serial number: 20140121211435
   Coding: 5D2401
   Shop #: WSC 06325 000 00000
   VCID: 26140A3FD8EFB6FA057-8072

4 Faults Found:
00381 - Databus Instrument Cluster
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 5
                    Fault Frequency: 8
                    Reset counter: 236
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:20

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        Start
                    Count: 2
                    Temperature: 2.0 C
                    RPM: 0 /min
                        Yes

01314 - Engine Control Module
            013 - Check DTC Memory
             Freeze Frame:
                    Fault Status: 01101101
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 196
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:21

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        Start
                    Count: 2
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No

00003 - Control Module
            014 - Defective - Intermittent
             Freeze Frame:
                    Fault Status: 00101110
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:18

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        OFF
                    Count: 0
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No

02251 - Heater Unit Locked
            000 - -
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:22

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        OFF
                    Count: 0
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No


-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 8T0-907-468.clb
   Part No SW: 8R0 907 468 P    HW: 8R0 907 468 D
   Component: GW-BEM 5CAN-M H11 0060
   Revision: 1Z120030    Serial number: 3041Z141310364
   Coding: 80CF07FF00
   Shop #: WSC 06325 000 00000
   VCID: 4CC0989766C3ACAAF33-8018

   Subsystem 1 - Part No SW: 8T0 915 181     HW: 8T0 915 181
   Component: J367-BDMHella  H03 8041
   Serial number: 8456902503        

   Subsystem 2 - Part No SW: 8K0 959 663     HW: 8K0 959 663
   Component: J532_DCDCStab  H17 0042
   Serial number: 14042004411011200181

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:. 8K0-959-793.clb
   Part No SW: 8K0 959 793 R    HW: 8K0 959 793 P
   Component: TSG FA        H02 0510
   Revision:             Serial number: 0000091081024
   Coding: 011C02204000410001
   Shop #: WSC 06325 000 00000
   VCID: 4FFA8F9B97D597B2961-801A

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist (J500)       Labels:| 8K0-909-144.clb
   Part No SW: 8K0 909 144 G    HW: 8K0 909 144 B
   Component: RCEPS         H40 0508
   Revision: 00001000    Serial number: 0006286763 Dataset Number: 8K0909852J  0024
   Coding: 100001000001
   Shop #: WSC 06324 000 00000
   ASAM Dataset: EV_RCEPSAU48X 008015
   ROD: EV_RCEPSAU48X_008.rod
   VCID: 3536DD7315C9CD62BCD-8060

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. (J393)       Labels:. 8K0-907-064-46.clb
   Part No SW: 8K0 907 064 JD    HW: 8K0 907 064 JD
   Component: BCM2 2.0      H14 0650
   Revision: 00002001    Serial number: 0326182743  
   Coding: 0100062820B900008320023680000047
   Shop #: WSC 06325 000 00000
   VCID: 7BA20B4B73EDDB120A9-802E

2 Faults Found:
02616 - Fuel Tank Cap; Unlock
            009 - Open or Short to Ground - Intermittent
             Freeze Frame:
                    Fault Status: 00101001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 90
                    Mileage: 317900 km
                    Time Indication: 0
                    Date: 2025.01.18
                    Time: 14:22:13

02615 - Fuel Tank Cap; Lock
            009 - Open or Short to Ground - Intermittent
             Freeze Frame:
                    Fault Status: 00101001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 90
                    Mileage: 317973 km
                    Time Indication: 0
                    Date: 2025.01.18
                    Time: 15:15:07


-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:. 8K0-959-792.clb
   Part No SW: 8K0 959 792 R    HW: 8K0 959 792 P
   Component: TSG BF        H02 0510
   Revision:             Serial number: 0000091280873
   Coding: 011C02204000410001
   Shop #: WSC 06325 000 00000
   VCID: 4EC4929F90DF9EBA9D7-801A

No fault code found.

-------------------------------------------------------------------------------
Address 53: Parking Brake (----)       Labels: 8K0-907-801-V2.clb
   Part No SW: 8K0 907 801 N    HW: 8K0 907 801 J
   Component: EPB-4         H01 0005
   Revision: --------    Serial number: 00000001435263
   ASAM Dataset: EV_ParkiBrake 001028
   ROD: EV_ParkiBrake_AU48.rod
   VCID: 3A2CCE4F3CD7221A51F-806E

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (R)       Labels:. 4F0-035-0xx-56.clb
   Part No SW: 4G0 035 056 J    HW: 4G0 035 056
   Component: Radio U STD   H60 0133
   Revision: AB001007    Serial number: 230BT0E2984423
   Coding: 010003020100000001
   Shop #: WSC 06325 000 00000
   VCID: 28080407D2FBA08A37B-807C

No fault code found.

-------------------------------------------------------------------------------
Address 5C: Lane Maintain.        Labels: None
   Part No SW: 8T0 907 217 A    HW: 4E0 907 217 C
   Component: J759 HC             0040
   Revision: 00H08006    Serial number: 60021421100133
   Coding: 0102001
   Shop #: WSC 06325 000 00000
   VCID: 372AD77B03453F72AE1-8062

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels:. 4E0-035-6xx-5F.clb
   Part No SW: 8R1 035 670 E    HW: 8R1 035 670 E
   Component: H-BNT-EU      H48 0793
   Revision: --------    Serial number: 207B.0E7575651
   Coding: 0F0100010006ABED2980EB5E00000403040000000000000000
   Shop #: WSC 06325 000 00000
   VCID: 3536DD731549CD62BCD-8060

   Subsystem 1 - Part No: 8R0 060 884 BK
   Component: EUR 2014  1703

   Subsystem 2 - Part No SW: 8R0 919 604 A    HW: 8R0 919 604 A
   Component: DU7 High  H42 0104
   Serial number: A130BE0E2943000    

   Subsystem 3 - Part No SW: 8T0 919 611 K    HW: 8T0 919 611 B
   Component: E0380 Bedient  H02 0030
   Serial number: 00000001756601    

   Subsystem 4 - Part No: 8R0 060 961 F
   Component: CD-Database  5571

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left (J388)       Labels:. 8K0-959-795.clb
   Part No SW: 8K0 959 795 G    HW: 8K0 959 795 D
   Component: TSG HL        H01 0510
   Revision:             Serial number: 0000091011879
   Coding: 010C02204000210001
   Shop #: WSC 06325 000 00000
   VCID: 46D4AABF78AF56FA257-8012

No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer (J345)       Labels:. 8K0-907-383.clb
   Part No SW: 8K0 907 383 E    HW: 8K0 907 383 E
   Component: Anhaenger     H09 0100
   Revision: 1A001001    Serial number: 00000325777552
   Coding: 010D000000000000
   Shop #: WSC 25381 000 00000
   VCID: 3634DA7F084FC67AB57-8062

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right (J389)       Labels:. 8K0-959-795.clb
   Part No SW: 8K0 959 795 G    HW: 8K0 959 795 D
   Component: TSG HR        H01 0510
   Revision:             Serial number: 0000091011878
   Coding: 010C02204000210001
   Shop #: WSC 06325 000 00000
   VCID: 46D4AABF78AF56FA257-8012

No fault code found.

End----(Elapsed Time: 01:42, VBatt start/end: 12.1V/11.9V. VIgn 12.0V)-----

Log 2 (335.000 km, after EGR replacement)
Code:
Friday,07,November,2025,18:18:06:35772
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 11 x64
VCDS Version: 24.7.1.0 (x64)  HEX-V2 CB: 0.4643.4
Data version: 20240919 DS356.3
www.Ross-Tech.com


VIN: WAUZZZ8K2EA119576
Mileage: 335490km-208463mi   Repair Order:



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


Chassis Type: 8K-AU48 (8R0)
Scan: 01 02 03 05 08 09 13 15 16 17 18 19 42 44 46 52 53 56 5C 5F
          62 69 72

VIN: WAUZZZ8K2EA119576   Mileage: 335490km-208463miles

01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
13-Auto Dist. Reg -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
18-Aux. Heat -- Status: Malfunction 0010
19-CAN Gateway -- 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
53-Parking Brake -- Status: OK 0000
56-Radio -- Status: OK 0000
5C-Lane Maintain. -- Status: OK 0000
5F-Information Electr. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
69-Trailer -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CGLC)       Labels:. 03L-906-018-CGL.clb
   Part No SW: 03L 906 018 JJ    HW: 03L 906 018 JL
   Component: R4 2.0l TDI   H25 9978
   Revision: 45H25---    CVN: E2F673E6
   Coding: 1203401A245401080000
   Shop #: WSC 00649 002 1048576
   ASAM Dataset: EV_ECM20TDI01103L906018JJ 003010
   ROD: EV_ECM20TDI01103L906018JJ.rod
   VCID: 7BA20B4B736DDB120A9-802E
   VINID: 9D196AAAA21B09544104914718ECDEE6F3

1 Fault Found:
4807 - EGR System
          P0401 00 [11101000] - Insufficient Flow
          MIL ON - Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 335473 km
                    Date: 2025.11.04
                    Time: 17:25:17

                    Engine RPM: 1398.00 /min
                    Normed load value: 32.9 %
                    Vehicle speed: 38 km/h
                    Coolant temperature: 73  C
                    Intake air temperature: 21  C
                    Ambient air pressure: 1010 mbar
                    Voltage terminal 30: 14.680 V
                    Unlearning counter according OBD: 40
                    Air mass: specified value: 280.0 mg/stroke
                    Air mass: actual value (mg/stroke): 432.1 mg/stroke
                    EGR Solen.val.: actual value: 16.15 %
                    Throttle valve adapter: actual value: 25.37 %
                    Charge air pressure: specified value: 1068 hPa
                    Charge air pressure: actual value: 1161 hPa
                    Mean injection quantity: 10.90 mg/stroke

Readiness: 1 1 0 0 0

-------------------------------------------------------------------------------
Address 02: Auto Trans (J217)       Labels:| 0AW-927-156.clb
   Part No SW: 8K5 927 155 L    HW: 0AW 927 156 K
   Component: 0AW_20TDI_RdW H06 0004
   Revision: --H06---    Serial number: 0000001226 CVN: 0000FFE2
   Coding: 000002
   Shop #: WSC 06325 000 00000
   ASAM Dataset: EV_TCMVL381 A02433
   ROD: EV_TCMVL381.rod
   VCID: 41DEB9A3510171C2105-8014

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 8K0-907-379-V2.clb
   Part No SW: 8K0 907 379 CN    HW: 8K0 907 379 CN
   Component: ESP8 front    H09 0020
   Revision: --------    Serial number: --------------
   Coding: 179DCC01
   Shop #: WSC 06325 000 00000
   VCID: 074A67BB3F258FF21E1-8052

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. (J393)       Labels:. 8K0-907-064-05.clb
   Part No SW: 8K0 907 064 JD    HW: 8K0 907 064 JD
   Component: BCM2 2.0      H14 0650
   Revision: 00002001  
   Coding: 01A24000000000000000
   Shop #: WSC 06325 000 00000
   VCID: 7BA20B4B73EDDB120A9-802E

   Subsystem 1 - Part No SW: 8K0 959 754 H    HW: 8K0 959 754 H
   Component: FBSAUDIB8 IDG  H71 0083
   Serial number: 0514000021869019  

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:. 8Kx-820-043-3Z.clb
   Part No SW: 8K1 820 043 AJ    HW: 8K1 820 043 AJ
   Component: KLIMA 3 ZONEN H04 0123
   Revision: C1000000    Serial number: 01080220141186
   Coding: 342800A000
   Shop #: WSC 06325 000 00000
   VCID: 70B82C672AABA84AAFB-8024

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 8K0-907-063.clb
   Part No SW: 8K0 907 063 DH    HW: 8K0 907 063 DH
   Component: BCM1 1.0      H16 0103
   Revision: 08016001    Serial number: 00000061963802
   Coding: 260000108034AFC00081400300001D0D0F1C670826090201000008004401020100000024000000
   Shop #: WSC 06325 000 00000
   VCID: 78A8144742DBF00A67B-802C

   Subsystem 1 - Part No SW: 8K1 955 119 B    HW: 8K1 955 119 B  Labels: 1KX-955-119.CLB
   Component: MITSUBA200114  H18 0461
   Serial number: 1401150707796      
   Coding: 004577

   Subsystem 2 - Part No SW: 8U0 955 559 B    HW: 8U0 955 559 B  Labels: 8U0-955-559.CLB
   Component: G397_RLFS  H06 0002
   Serial number: 22252182          
   Coding: 02005D

   Subsystem 3 - Part No SW: 8K0 941 531 AS    HW: 8K0 941 531 AS
   Component: E1 - LDS  H03 0031
   Serial number: 00000000000802140704

   Subsystem 4 - Part No SW: 4H0 907 658     HW: 4H0 907 658
   Component: AQ_Hum_Sensor  H03 0003
   Serial number: 6E380117000000000001

No fault code found.

-------------------------------------------------------------------------------
Address 13: Auto Dist. Reg (J428)       Labels: None
   Part No SW: 8K0 907 561 B    HW: 8K0 907 561 B
   Component: ACC3          H11 0100
   Serial number: 00000000000000
   Coding: 00F2D1
   Shop #: WSC 06325 000 00000
   VCID: 313EE963E121E142E05-8064

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 8K0-959-655.clb
   Part No SW: 8K0 959 655 N    HW: 8K0 959 655 N
   Component: AirbagVW-AU10 H47 0610
   Serial number: 003KFDB4CD7C   Dataset Number: 8K0909602Q  0001
   Coding: 30524435363030303030554A304C384B3053
   Shop #: WSC 33640 001 1048576
   ASAM Dataset: EV_AirbaECUVWAUDI010 003010
   ROD: EV_AirbaECUVWAUDI010_003_AU48.rod
   VCID: 48C8A487723B408AD7B-801C

   Crash sensor for side airbag: driver side:
   Serial number: 6334MSME433B7A69Q

   Front Passenger's Side Airbag Crash Sensor:
   Serial number: 6344MSME422C407EJ

   Rear Side Airbag Crash Sensor (on driver's side):
   Serial number: 6352QSME46402868F

   Passenger side rear thorax airbag crash sensor:
   Serial number: 6362QSME0A42585AM

   Crash sensor for front airbag: driver side:
   Serial number: 63732SME343D09660

   Crash sensor for front airbag: front passenger side:
   Serial number: 63832SME723C19641

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:. 8K0-953-568.clb
   Part No SW: 8K0 953 568 M    HW: 8K0 953 568 M
   Component: Lenks.Modul   H04 0005
   Revision: --------    Serial number: 90372NBA001CT
   Coding: 0000DF
   Shop #: WSC 06325 000 00000
   VCID: 44D0B0B74E9364EA3B3-8010

   Component: E221 - MFL  H03 0004

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:. 8T0-920-xxx-17.clb
   Part No SW: 8K0 920 932 A    HW: 8K0 920 932 A
   Component: KOMBIINSTR.   H35 0564
   Revision: 00200000    Serial number: ZCH53GD2F    
   Coding: 13E6100047010008000000
   Shop #: WSC 06325 000 00000
   VCID: 2D06F513FD1985A2C4D-8078

No fault code found.

-------------------------------------------------------------------------------
Address 18: Aux. Heat (J364)       Labels:. 8R0-265-105.clb
   Part No SW: 4H0 265 105 G    HW: 4H0 265 105 G
   Component: Standheizung  H24 0260
   Revision: 66006006    Serial number: 20140121211435
   Coding: 5D2401
   Shop #: WSC 06325 000 00000
   VCID: 26140A3FD8EFB6FA057-8072

4 Faults Found:
00381 - Databus Instrument Cluster
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 5
                    Fault Frequency: 8
                    Reset counter: 236
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:20

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        Start
                    Count: 2
                    Temperature: 2.0 C
                    RPM: 0 /min
                        Yes

01314 - Engine Control Module
            013 - Check DTC Memory
             Freeze Frame:
                    Fault Status: 01101101
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 196
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:21

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        Start
                    Count: 2
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No

00003 - Control Module
            014 - Defective - Intermittent
             Freeze Frame:
                    Fault Status: 00101110
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:18

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        OFF
                    Count: 0
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No

02251 - Heater Unit Locked
            000 - -
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 147874 km
                    Time Indication: 0
                    Date: 2018.03.29
                    Time: 20:48:22

             Freeze Frame:
                    Temperature: 2.0 C
                    Temperature: 5.0 C
                    Voltage: 3.80 V
                        OFF
                    Count: 0
                    Temperature: 2.0 C
                    RPM: 0 /min
                        No


-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 8T0-907-468.clb
   Part No SW: 8R0 907 468 P    HW: 8R0 907 468 D
   Component: GW-BEM 5CAN-M H11 0060
   Revision: 1Z120030    Serial number: 3041Z141310364
   Coding: 80CF07FF00
   Shop #: WSC 06325 000 00000
   VCID: 4CC0989766C3ACAAF33-8018

   Subsystem 1 - Part No SW: 8T0 915 181     HW: 8T0 915 181
   Component: J367-BDMHella  H03 8041
   Serial number: 8456902503        

   Subsystem 2 - Part No SW: 8K0 959 663     HW: 8K0 959 663
   Component: J532_DCDCStab  H17 0042
   Serial number: 14042004411011200181

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:. 8K0-959-793.clb
   Part No SW: 8K0 959 793 R    HW: 8K0 959 793 P
   Component: TSG FA        H02 0510
   Revision:             Serial number: 0000091081024
   Coding: 011C02204000410001
   Shop #: WSC 06325 000 00000
   VCID: 4FFA8F9B97D597B2961-801A

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist (J500)       Labels:| 8K0-909-144.clb
   Part No SW: 8K0 909 144 G    HW: 8K0 909 144 B
   Component: RCEPS         H40 0508
   Revision: 00001000    Serial number: 0006286763 Dataset Number: 8K0909852J  0024
   Coding: 100001000001
   Shop #: WSC 06324 000 00000
   ASAM Dataset: EV_RCEPSAU48X 008015
   ROD: EV_RCEPSAU48X_008.rod
   VCID: 3536DD7315C9CD62BCD-8060

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. (J393)       Labels:. 8K0-907-064-46.clb
   Part No SW: 8K0 907 064 JD    HW: 8K0 907 064 JD
   Component: BCM2 2.0      H14 0650
   Revision: 00002001    Serial number: 0326182743  
   Coding: 0100062820B900008320023680000047
   Shop #: WSC 06325 000 00000
   VCID: 7BA20B4B73EDDB120A9-802E

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:. 8K0-959-792.clb
   Part No SW: 8K0 959 792 R    HW: 8K0 959 792 P
   Component: TSG BF        H02 0510
   Revision:             Serial number: 0000091280873
   Coding: 011C02204000410001
   Shop #: WSC 06325 000 00000
   VCID: 4EC4929F90DF9EBA9D7-801A

No fault code found.

-------------------------------------------------------------------------------
Address 53: Parking Brake (----)       Labels: 8K0-907-801-V2.clb
   Part No SW: 8K0 907 801 N    HW: 8K0 907 801 J
   Component: EPB-4         H01 0005
   Revision: --------    Serial number: 00000001435263
   ASAM Dataset: EV_ParkiBrake 001028
   ROD: EV_ParkiBrake_AU48.rod
   VCID: 3A2CCE4F3CD7221A51F-806E

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (R)       Labels:. 4F0-035-0xx-56.clb
   Part No SW: 4G0 035 056 J    HW: 4G0 035 056
   Component: Radio U STD   H60 0133
   Revision: AB001007    Serial number: 230BT0E2984423
   Coding: 010003020100000001
   Shop #: WSC 06325 000 00000
   VCID: 28080407D2FBA08A37B-807C

No fault code found.

-------------------------------------------------------------------------------
Address 5C: Lane Maintain.        Labels: None
   Part No SW: 8T0 907 217 A    HW: 4E0 907 217 C
   Component: J759 HC             0040
   Revision: 00H08006    Serial number: 60021421100133
   Coding: 0102001
   Shop #: WSC 06325 000 00000
   VCID: 372AD77B03453F72AE1-8062

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels:. 4E0-035-6xx-5F.clb
   Part No SW: 8R1 035 670 E    HW: 8R1 035 670 E
   Component: H-BNT-EU      H48 0793
   Revision: --------    Serial number: 207B.0E7575651
   Coding: 0F0100010006ABED2980EB5E00000403040000000000000000
   Shop #: WSC 06325 000 00000
   VCID: 3536DD731549CD62BCD-8060

   Subsystem 1 - Part No: 8R0 060 884 BK
   Component: EUR 2014  1703

   Subsystem 2 - Part No SW: 8R0 919 604 A    HW: 8R0 919 604 A
   Component: DU7 High  H42 0104
   Serial number: A130BE0E2943000    

   Subsystem 3 - Part No SW: 8T0 919 611 K    HW: 8T0 919 611 B
   Component: E0380 Bedient  H02 0030
   Serial number: 00000001756601    

   Subsystem 4 - Part No: 8R0 060 961 F
   Component: CD-Database  5571

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left (J388)       Labels:. 8K0-959-795.clb
   Part No SW: 8K0 959 795 G    HW: 8K0 959 795 D
   Component: TSG HL        H01 0510
   Revision:             Serial number: 0000091011879
   Coding: 010C02204000210001
   Shop #: WSC 06325 000 00000
   VCID: 46D4AABF78AF56FA257-8012

No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer (J345)       Labels:. 8K0-907-383.clb
   Part No SW: 8K0 907 383 E    HW: 8K0 907 383 E
   Component: Anhaenger     H09 0100
   Revision: 1A001001    Serial number: 00000325777552
   Coding: 010D000000000000
   Shop #: WSC 25381 000 00000
   VCID: 3634DA7F084FC67AB57-8062

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right (J389)       Labels:. 8K0-959-795.clb
   Part No SW: 8K0 959 795 G    HW: 8K0 959 795 D
   Component: TSG HR        H01 0510
   Revision:             Serial number: 0000091011878
   Coding: 010C02204000210001
   Shop #: WSC 06325 000 00000
   VCID: 46D4AABF78AF56FA257-8012

No fault code found.

End----------(Elapsed Time: 01:42, VBatt start/end: 12.3V/12.1V)-----------
 
Last edited:
   #2  

Crasher

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Which make and part number of EGR valve did he fit?

Go into measuring blocks, take a note of the DPF soot and ash figures and post them.
 
   #3  

Byte

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I checked under the hood and on the repair invoice, but unfortunately I couldn’t find the make or part number. I forgot to mention; he replaced the EGR valve and cooler in one go.


I wasn’t sure which exact parameters to take regarding soot and ash mass, so I included a few additional ones as well.
 

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   #4  

Vdub

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a clogged EGR wont do anything to the Particletest of the Dutch APK, probably its just a broken DPF.
The problem with the EGR has a pipe from the exhaust to the intake, so only replace EGR(valve?) maybe isnt the solution.

The DPF values look if the DPF is almost full, 0,25L and over 80gr is with a 2.0TDI normally the beginning of the end off the DPF, but it doesnt need to set a DPF-fault.
 
   #5  

Crasher

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I can't remember the max ash max figure but 103 grams must be getting there. The soot is OK but could do with a service regen.
 
   #6  

Byte

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Thanks for your help! What would you guys advise? Should I replace the DPF, or is it worth trying a DPF cleaner and a forced regeneration first?
 
   #7  

Dr Sheldon

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You have an EGR fault after EGR Replacement

1 Fault Found: 4807 - EGR System P0401 00 [11101000] - Insufficient Flow

Does that not raise any suspicion with you ?

Has a bad / wrong part been fitted or fitted wrong ?

The EXACT same DTC before fitting the EGR !


"Insufficient flow" is not a vague description - it is a very clear description of what it is !!

Is there a blockage someplace - although that is on your so called mechanic to have determined at the start !!

Mechanic suspected an air leak ->
Where did you find that pest ?


Dont worry about the DPF - that will never be right until the EGR fault is resolved. The DPF can be chemically cleaned if it is not cracked / physically damaged.
 
   #8  

Dr Sheldon

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Thanks for your help! What would you guys advise? Should I replace the DPF, or is it worth trying a DPF cleaner and a forced regeneration first?
Again !! Resolve the EGR issue first !!!
 
   #9  

Crasher

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A DPF clean on the car won't help with Ash, only Soot; to even get around half of the Ash out they have to be cleaned on special high flow high temperature cleaning machines. You really need to find out some details of the EGR unit that was fitted.
 
   #10  

Byte

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Thanks for your help guys. I will bring the car to the mechanic again and mention about the EGR issue which is still there.
 
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