EGR should we all be more concerned

[HiTorque]

Is the engine chipped or reflashed for more power than stock?

Stock 100%, I got new EGR valve and flap motor, hate going through this again in 4 years time, and I don't know for sure if I picked up that shty diesel fuel from Caltex or this is what every mkV diesel owner should expect..

[neil]

Stock 100%, I got new EGR valve and flap motor, hate going through this again in 4 years time, and I don't know for sure if I picked up that shty diesel fuel from Caltex or this is what every mkV diesel owner should expect..

HiTorque what was the engine doing for you to realize you had a problem with the EGR.

[HiTorque]

HiTorque what was the engine doing for you to realize you had a problem with the EGR.

I didn't feel any noticeable difference. I got amber warning light and a message "Emissions Workshop" and then I stopped the music and started listening to the engine. I would say perhaps it was a bit noisier, but that would be it. It happened after 3-4 minutes drive on Friday night and I dropped car to the dealer following Monday. I got into EGR parts and took some photos that weekend. They replaced EGR motor, but didn't say a word about EGR valve. So I got the car back and after 100 km drive I got the same warning light and the same message, drove car back and they replaced EGR valve. Total cost would be around $1,800, but VWA contributed 50% in my case.
I would like mkV diesel owners to inspect their EGR parts and post their findings if its possible. If someone else has the same problem then we can discuss this further. According to the dealer (I don't want to name them here) they have 2-3 such cases a month, but this can be either correct figure or not...

[greygolf8]

Not being a mechanic, is there an easy way to inpsect the EGR parts ie remove a hose, or is it numerous parts .... ?

[HiTorque]

Not being a mechanic, is there an easy way to inpsect the EGR parts ie remove a hose, or is it numerous parts .... ?

Mate, I would suggest getting someone like licensed mechanic to do this job.
1. You need special tools, otherwise after some time spent you will hate everything about VW, I still didn't cool down...
2. You will need to buy two O-rings from VW parts that go on EGR motor and EGR valve and re-new existing ones
3. If something goes wrong he would be able to put everything back together
4. It took me over three hours to get this done including cleaning, but it was too late for the damage, I could not get EGR valve working.

[HiTorque]

These russians had similar issue and as far as I could understand from photos they had to make parts of EGR valve from something else, interesting idea IMO:

http://volkswagen.msk.ru/forum/index...howtopic=82248

[Greg Roles]

Interesting find, looks like they had to rebuild the diaphram for the valve. sadly it shows a fault in English on the first post as "EGR insufficient flow" so if we hobble the EGR flow, it's going to throw an error....

[Transporter]

I found the file about NOx and DPF.
Here is the link.

http://www.mediafire.com/?sharekey=2...4e75f6e8ebb871

[HiTorque]

Interesting find, looks like they had to rebuild the diaphram for the valve. sadly it shows a fault in English on the first post as "EGR insufficient flow" so if we hobble the EGR flow, it's going to throw an error....

Apparently prior to PD version (2.0TDI mkV) it was possible just to block EGR system, many people in UK forum did it without any issues. Also someone suggested cleaning method - driving in 3 gear at 100-110km/h for 30 km.

[Transporter]

I wouldn't do that very often.
It would put more wear on the gearbox and the engine.