Help required to diagnose egr/ manifold fault Scotland

cheechy

A2OC Donor
I've gone on about this a few times in the last few weeks but could really do with a trained eye north of the border to help me accurately diagnose current issue. Yes I know I could take to a VAG specialist but I'll be honest I've spent 1000s on repairing and doing this car up and I'm at my limit on what I'm prepared to throw on this particular bonfire. Indeed way beyond.

I've had kind offers from members in the north of England ( you know who you are) but I've done many miles driving down there and to Wales to get stuff and don't want to take the pilgrimage again anytime in next few months.

Any experienced members able to give me an hour or so of their time (for an a agreed amount of course) to not only help diagnose but help educate? Once diagnosed I can then look to try and self repair. Alas I'm way beyond my current knowledge and fear professional diagnosis of something this complex may cost a packet and not even produce a result.

To summarise this is an atl tdi 90. EML light illuminated with scan highlighting the manifold intake. Changed but error came back. Now expanded to include limit exceeded on EGR despite remap bypassing it.

Manifold intake is working as the car shuts down without shaking very smooth.

I'm guessing I could be left with the following to look at:

- hoses - loose/ cracked
- intercooler?
- Maf
- electrical issue?

Thanks for reading :)
 
Do you have the actual scan results?

They may assist in remotely troubleshooting the issues.
Scan results from VCDS are required, not from a generic code reader, and the full scan is always best, rather than just sub-section.

Cheers
Jeff
 
I guess this illustrates my point to a degree.

I've been using obd eleven which does a simple lookup I guess all be it it is more useful than a generic reader.

Anyone local who could do a full scan?
 
I guess this illustrates my point to a degree.

I've been using obd eleven which does a simple lookup I guess all be it it is more useful than a generic reader.

Anyone local who could do a full scan?

Okay - you really need a proper scan so an accurate picture of the cars health can be obtained.

Another good thing might be to elaborate on your original post.
You seem to suggest you've thrown some serious money at the car up to now, but it's not clear if all of this expense is trying to resolve your current dilema, or if it's just been spent doing a multitude of other work.

If you could:
1. detail the symptons you are noticing and what (if any) errors or warning appear on the dash.
2. advise what has been tried to resolve said issue(s)
3. advise what sucess item 2 provided (little/none/partial)....you get the idea.....
4. advise if there was there anything that occured that brought on the current issue - for example, the car was okay, had a remap, next day issue started.......had a service and next day issue started.....again, you get the idea.
5. say how long have you been in posession of this car and do you know it's prior history of servicing or faults

You might want to advise if there any performance issues or exessive fuel consumption concerns.

Is this an intermittent issue, or is the issue present at all times.

Maybe also good to advise if you are able to take pictures of any dash errors/messages and maybe some of the engine bay as required.

Cheers
Jeff
 
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Thanks Jeff. No not on this issue but I have spent a lot on bringing the car back and just can't seem to stay on top if all the issues.

Basically I bought the car with no service history but banked on 1k to put things right. I did a scan when I purchased which at least gave me a number of codes / errors to knock that 1k off the asking price.

Water pump, cam belt, timing belt, discs, pads, aircon compressor, full service and a wide variety of sensors and other things have been bought and fitted in 6 months of ownership. I just really want to have the car running for a while without worrying if something serious is going to happen. I can live with the small stuff for now.

So to be fair I did a bit of self diagnosis on the replaced manifold intake. Unplugged to see the difference and whilst there was it wasn't much so took decision to replace. Shut off miles better but intermittent fault came back.

In cold weather I've seen the addition of egr limit exceeded as above. Thus far symptoms have been restricted to a couple of episodes of limp mode but I do fear impending doom.

I've inspected the hose to the manifold intake and couldn't see any splits. Aside from that as I say I lack the experience (and tools I guess) to pinpoint any other potential areas or indeed what to look for if I do know where to look.

I didn't really buy the car to make it into a fixing hobby but that's where it's gone.

In all fairness this car probably should have been broken up for spares but isn't hindsight great!
 
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Hi Cheechy,
Could I suggest investing a few quid (under £10) on one of the ebay VAGCOM cables, you will need a laptop running a 32bit version of Windows, win7 is fine or anything older back to XP is also good

This will then allow you to do a full scan and post up the results, I'm 100% with Jeff in that without a vagcom or VW Tools scan we are all shooting in the dark.

Obvious (to me) things to check are (a) all the vacuum hoses from the unit on the drivers side inner wing, these feed the turbo control valve, the EGR etc make sure that there are no holes worn in the pipes as they rub on a brake pipe etc and that all the ends are tight fit as the rubber may have relaxed over time and therefore not making an airtight seal
(b) the hoses from the turbo back to the inter cooler and to the air filter box
(c) the inter cooler itself especially the bottom of the inter cooler where the aluminium and plastic end mate, there is a rubber seal in there which can come out / leak as the aluminium allows the plastic end cap to disconnect. There is likely a fine oil mist around the inter cooler bottom is this is the problem
(d) the MAP sensor in the inter cooler
(f) the MAF sensor (clean it with carb cleaner)
(g) you have the VVT which is more complex than the earlier turbo fitted to the AMF/BHC engines. It is possible for the turbo vanes to gunge up and stick, taking it apart to clean it is an option, but getting it off the car is a challenge

Cheers,
Paul
PS loving the sports seats sooooooo much more comfortable on a long drive :)
and if all else fails I have a nice trouble free 282,200 Miles A2 (AMF engined) that I can part ex for your TDI 90 :)
 
A seized VNT mechanism will cause loss of performance and may also trigger limp mode, but it won't cause the EML to show, not at least in my experience. Same for pressure leaks in the pipework and intercooler. Is the problem caused by the disabled EGR? You know of course that this is illegal and might invalidate your insurance. The nearest I have come to a problem with EGR on all three cars is gumming up of the manifold, which also gets cleaned when the VNT mechanism needs cleaning.

RAB
 
The manifold is only around two months old and appears at least to be working perfectly in this case.
 
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Right so today eventually got round to plugging in laptop and VCDS. Tried doing a auto-scan and when it hits the brakes it all stops and asks me to cough up some dough :).

What modules should I scan to bring out the relevant codes here? Or is a license the only option - even for lite version its something like 70-75 quid looks like...ouch.
 
Right so today eventually got round to plugging in laptop and VCDS. Tried doing a auto-scan and when it hits the brakes it all stops and asks me to cough up some dough :).

What modules should I scan to bring out the relevant codes here? Or is a license the only option - even for lite version its something like 70-75 quid looks like...ouch.

Will be the 01 engine module I would think
I can’t see any other modules coming into play
Cheers


Sent from my iPhone using Tapatalk
 
Will be the 01 engine module I would think
I can’t see any other modules coming into play
Cheers


Sent from my iPhone using Tapatalk

I cleared the codes down a few days back - EML light came on then went off again yesterday. Scan on 01 module says no faults found! Will need to scan again when light is back on - but I suspect the code will be as reported above.

Aside from glass breakage sensor for rear (which I know about and is on my list - changed lights and didn't refit trim properly I suspect) we have the temp flap motor back at intermittent!
 
It sounds to me that your turbo and egr valve are gunked up hence going into limp mode. I had this on our A4 tdi that just got worse over time. Look on youtube for these type of problems and how to repair. Here's a couple for now.I Just had a very quick look for you but you get the picture.

https://youtu.be/Ppif4qC560U

This one is just a generic example but it shows the general way.

https://youtu.be/TZDsdM571_M

This should help.
 
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