CEL code P0401, dealer says EGR only, DPF fine. Soot in tailpipe.

Got Haggis?

Veteran Member
Joined
Oct 14, 2002
Location
Baltimore, Maryland
TDI
2011 Golf DSG
Let me recount my experience taking my 2011 golf tdi with 68k miles on it to the dealer. Based on what I have read on this forum, I expected the dealer to replace the DPF and EGR under the 80k federal emissions warranty. I arrive this morning at about 9:30am, only 2 other people waiting. I didn't drop off, I was mainly waiting for them to tell me it was covered under warranty and then I will drop it off later in the week for them to replace it.

3 hours of waiting, the service adviser comes out to tell me that I have two problems, one is the EGR code and the other is the recirculation flap motor. The recirculation flap motor isn't under warranty and would cost $800 to replace (what). I think this was some sort of mistake in price, but whatever. I can deal with foggy windows and I saw the youtube video that shows how to replace it. seems easy enough.

They tell me they have to do some testing to see if the DPF was the result of the EGR failure.

So after waiting another 3 hours, they come out to tell me that the DPF tested out fine and its just the EGR, therefore I will need to foot the bill.

I agrued that this can't be the case, as there is soot in my tailpipe and that almost certainly points to a cracked DPF (i'm no mechanic of course, I'm just basing this on what I have read here)

After a bit of discussion, she says that I will need to bring the car back in later in the week so "the director" can look at it himself to make the call. But that if they replace the DPF on VW's dime and send it back to them for testing and it turns out its fine, they would be billed for it...so they don't want to do that since according to their tests, my DPF is fine.

Does this sound correct at all? It seems to me that based on the soot alone, the DPF must be cracked. I have no idea what type of testing they did...I guess I'm just looking for anything I can give them that says it should be covered under warranty.

I was really unhappy with this service adviser, giving me no updates on my car at all (I certainly would not have waited there for 6 freaking hours had I known it was going to take that long - 3 hours into it, she told me 'just a bit longer') - and then they give me keys to someone elses car when they said my car was ready (and my car was no where in sight). I can't wait not to "deal" with dealerships anymore.

If it really is possible that only the EGR failed, I guess I'll do the DPF delete....I am just having a difficult time believing that is the case based on all that I've read here.
 

VeeDubTDI

Wanderluster, Traveler, TDIClub Enthusiast
Joined
Jul 2, 2000
Location
La Conner, WA
TDI
2018 Tesla Model 3: 217,000 miles
In all likelihood, your dealer is full of snot.

How much soot is in your tail pipe? Is it getting the back bumper dirty? If so, then your DPF is most likely cracked. EGR filters don't just clog up for no reason, and the cascading failure of a cracked DPF causing a clogged EGR filter has been documented many times here.

As for the price of the exhaust flap repair, that's an insane price for something that you can do on your own without too much hassle. Parts are listed below:

IDParts:
Valve ($230): http://idparts.com/catalog/product_info.php?products_id=2502
Gasket kit ($12): http://idparts.com/catalog/product_info.php?products_id=3269
Clamp ($60): http://idparts.com/catalog/product_info.php?products_id=3270

World Impex:
Exhaust valve ($258): http://www.worldimpex.com/parts/genuine-part-exhflap_3689184.html
Gasket kit ($6): http://www.worldimpex.com/parts/genuine-part-gasket_916834.html
Clamp ($47): http://www.worldimpex.com/parts/genuine-part-clip_916838.html
 

meerschm

Top Post Dawg
Joined
Apr 18, 2009
Location
Fairfax county VA
TDI
2009 Jetta wagon DSG 08/08 205k buyback 1/8/18; replaced with 2017 Golf Wagon 4mo 1.8l CXBB
I think he is talking about an hvac control flap in the dashboard area.

I would take a copy of the TSB into the dealer.

it has nice photos and clear instructions to replace the DPF if there is any soot in the EGR

"Remove the EGR filter from the DPF and swipe the inside of the exhaust pipe at the EGR filter connection point using a clean cloth or your finger. See figures 1 and 2.
If your finger or the cloth comes out with black soot, replace the DPF & EGR filter together."
 

scdevon

Veteran Member
Joined
Jan 19, 2011
Location
USA
TDI
None
Any amount of visible soot in the tailpipe = automatic cracked DPF on a 100% stock car plus an automatic clogged EGR filter. There is no other possibility.

Replacing only the EGR filter will result in another clogged filter in a few thousand miles. Fact.
 

YukonLT

Veteran Member - TDIClub Enthusiast
Joined
Nov 28, 2012
Location
N/A
TDI
2010 Golf TDI 6MT
Your DPF is toast, don't let them tell you any different.
 

Got Haggis?

Veteran Member
Joined
Oct 14, 2002
Location
Baltimore, Maryland
TDI
2011 Golf DSG
update: they said they did the test by swiping their finger in where the EGR connection is and there was no soot (but there is soot if I swipe my finger at the end of the tailpipe) therefore not covered under warranty

I'm still having discussions with them, may have to call VW.

I guess its possible the egr just failed without the dpf going bad/cracked?
 

Got Haggis?

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Joined
Oct 14, 2002
Location
Baltimore, Maryland
TDI
2011 Golf DSG
The main problem with that is that they will charge $100+ if it turns out not to be covered under warranty (just for the code read) This dealer didn't charge me because it took them so long, but said in the future they will charge.
 

Got Haggis?

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Joined
Oct 14, 2002
Location
Baltimore, Maryland
TDI
2011 Golf DSG
another update: just got off the phone with the service director that gave me more information.

he said the problem is that the EGR pipe is cracked, not the DPF, therefore not covered under warranty - and the soot in my tailpipe is normal (back bumper isn't covered with soot, just some in the tailpipe) - $520 to replace.

he kind of hinted that i should probably just drive it and if the DPF happens to fail before 80k miles, then it would all be covered under warranty

has anyone else had this happen (cracked pipe?) it said it was basically where the weld was. and are there any downsides to not getting it fixed?
 

VeeDubTDI

Wanderluster, Traveler, TDIClub Enthusiast
Joined
Jul 2, 2000
Location
La Conner, WA
TDI
2018 Tesla Model 3: 217,000 miles
If the EGR supply tube is indeed cracked, then it could cause the P0401 code, which is EGR insufficient flow.
 

Got Haggis?

Veteran Member
Joined
Oct 14, 2002
Location
Baltimore, Maryland
TDI
2011 Golf DSG
update: so i drove the car around for months with this light on. I finally took it to a different dealership this morning - and they diagnosed it as a cracked DPF, covered under warranty.

so I guess i'll never take my car back to the original dealer I used (Heritage VW of Owings Mills MD)
 
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