I own a 2006 Jetta with the BRM engine and DSG. At 170k miles, it started to surge, had an unstable idle and eventually died and wouldn't start again. Upon readout of the codes I got:
1 Fault Found:
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction
and a MAF code of some sort.
insert long painful and expensive interaction with VW of Waldorf,MD here
Got the car back to my house. Took the anti-shudder valve and EGR valve assembly off. Found:
- the gears on the anti-shudder valve worn off and stripped
- EGR valve body assembly completely coked up with the valve stuck open (taking the valve itself out of the body required a chisel and prybars
- a small amount of oil in the rubber elbow, but not more than I would expect.
Cleaned up the EGR valve and put power to it and it would move some but never close completely. So I ordered replacements for both the anti-shudder and the EGR valve through IDIparts and installed them last night.
First trip this morning, the car smoked like a locomotive (white
) for a short while but then started to run smoothly and had a good throttle response except that it had no power. Boost would only go to about 1.45bar, no smoke. It would rev all the way to 4000rpm but just didn't accelerate well and topped out at about 55mph.
Pulled the codes, got a P0403 circuit intermittent error and when I looked at the EGR duty cycle I got numbers greater than 100% while driving. So it looked like I had still a stuck open EGR valve. So, with the valve itself eliminated, I figured it had to be the wiring. Pulled the plug off, soaked it in contact cleaner, dried it out and clicked it back in (may not have 'clicked' the first time on second thought).
Next test-drive, it smoked again like a locomotive, except that it was now black smoke !!! (that's good, right
Now it makes power just like it used to. 100hp is nothing write home about but enough for my mother in law to run around town (the main job of this car these days). I have yet to figure out how to actually create .csv log files with my vag-com, but it looks like I get about 1.85bar of boost and the EGR now does what I expect it to do and that is to cycle in the low percentages, 15-30% or so.
So, my question to the more knowledgeable:
- what boost should I expect at full 'throttle' ?
- what are the measurements of the screw that holds the EGR cooler to the EGR body. One of those suckers disappeared into nowhereland under the hood. Looks like M8x25 or thereabouts with a Allen head.
- anything else that comes to mind