EGR valve problem - advice requested

[Nicwix]

I've had a longstanding problem with my Golf V TDi 2.0 related to the EGR valve.

For a while, the car hicupped under load and emitted excessive black smoke. I had the EGR valve cleaned, but that didn't help. I then replaced it with a new one, but the problem remained.

I then thought to try and remove the vacuum tube from the valve, effectively stopping the EGR valve from opening. Lo and behold, the problem was fixed.

I blocked the vacuum tube and drove that way for a while and all was fine. After a few days, the yellow engine light came on as well as a message "Emissions Garage" on start. This was mildly irritating, but the car was driving fine, so I lived with it.

I now wish to sell the car and would like to resolve the problem. Any thoughts on what to try? The other end of the vacuum tube goes into a box with about 10 other tubes. I'm happy to have the EGR disabled, since the car drives well without black smoke, but I want the light to remain off (I have had it reset, but no doubt it will come on again). Alternatively, I'd like to fix the problem if that can be done a reasonable cost.

Any thoughts as to what I should do?

Thanks
Nic

[Bug_racer]

what fault codes are you getting ?

[Silva-Jetta]

As a final solution would recommend Malone Tuning (use Google to find out more)

Before I discovered the above solution I also disabled my EGR (removing and plugging the vacuum tube). Then just before every VW service I would reconnect it and clear the fault code (you need a VAGCOM for this - I use Ross-Tech).

Over the years I noticed my inlet manifold remained relatively clean and I had less exhaust smoke on heavy acceleration. However I got tired of the fault light being on all the time so I investigated a more eloquent solution.

It turned out to be a remap from Malone Tuning. Not only did I get rid of the EGR for good (and the fault light) but my car was blessed with more torque, more power, a longer glow plug on period and I am now able to keep the foot on the brake and hold the engine revs up a bit off the lights (I do not actually use this feature but it is there if I want it - btw this only applies to DSG trannies)

And if I want to I can remove this tune and put my car back to stock.

Actually, you may find that with the extra power on tap, you may not want to sell the car. I have had mine for 10 years and I will be keeping it until the bitter end.

[ThurmanMurman]

fault codes, please? Look these fellows may cause problem, wiring, short to ground, could MAF sensor also!

There are two Sensors
Sensor 1 G450 P/N = 076 906 051B
Sensor 2 G451 P/N = 03G 906 051G http://i.imgur.com/vfGc3sz.jpg

03G906051A
1K0906627A
1K0906283A

As per Bentley manual:

Exhaust Pressure sensor 1; g450, bolted to auxiliary fuel pump v393 bracket
Exhaust Pressure sensor 2: g451, bolted near oil filler neck


Install the sensor.
Do not start the car.
Open VCDS.
01- Engine
- Coding II
--Start Exhaust Pressure Sensor Adaptation
Run it.



I'm also getting Golf mk5 1.9tdi MIL ON:
001031 - EGR Sensor 2
P0407 - 000 - Signal too Low - Intermittent
Freeze Frame
Fault Status: 00100000
Fault Priority: 1
Fault Frequency: 61
Reset counter: 255
Mileage: 270014 km
Time Indication: 0
Date: 2000.00.00
Time: 16:41:26

Freeze Frame
RPM: 798 /min
Speed: 0.0 km/h
Load: 0.0 %
Lambda: -17.2 %
Mass Air / Rev.: 220.0 mg/str
Mass Air / Rev.: 445.0 mg/str
Bin. Bits: 00000000

[Umai Naa!!]

Those sensors aren't fitted to this model.

[Greg Roles]

Yep OP's car is the non DPF 103kw MKV version, the above sensors pertain to the 125kw / DPF version is mk V and beyond.

The odd thing is a replacement EGR valve didn't fix it, we do need the exact error codes to give any sort of useful diagnosis.