Exhaust Gas Recirculation (EGR) Problems 1.9 TDI

Hello everyone,

I have a Touran 1.9 TDI DSG manufactured in 02/2008 with the following error codes stored in the diagnostic memory:

Saturday, March 14, 2009, 00:02:46:07974
VCDS Version: DRV 812.3
Data as of: 20090224.



'Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein.'
'Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein.'


Vehicle type: 1K0
Scan: 01 02 03 08 09 15 16 17 18 19 25 3D 42 44 46 52 56 62 72 77


Vehicle Identification Number: WVGZZZ1TZ8W014727
Mileage: 124,450 km

01-Motor electronics -- Status: Error 0010.
02-Gearbox -- Status: OK 0000
03-Brake electronics -- Status: OK 0000
04-Steering angle sensor -- Status: OK 0000
08-Climate Control/Heating Unit -- Status: OK 0000
09-Central Electrical System -- Status: OK.
15-Airbag -- Status: OK 0000
16-Wheel Steering Electronics -- Status: OK 0000
17-Terminal block insert -- Status: OK 0000
18-Heater -- Status: OK 0000
19-Diagnosis interface -- Status: OK 0000.
Immobilizer system -- Status: OK 0000
3D Special Features -- Status: Error 0010.
42-Door Electric Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Comfort System -- Status: OK 0000
52-door electric passenger side door - Status: OK 0000.
56-Radio -- Status: OK 0000
62- Door, electric, left and right -- Status: OK 0000
72-Door, electric, high, right side -- Status: OK 0000.
77-Phone -- Status: OK 0000

'Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen.'
Address 01: Engine Control Module
Label file: DRV\03G-906-021-BLS.lbl
Part number SW: 03G 906 021 RM, hardware: 03G 906 021 CG.
Part: R4 1.9L EDC G000AG 1345
Revision: --H07--- Serial number: VWX7Z0G53N60K8
Encoding: 0000078
Operating number: WSC 01324 785 00200

2 error codes found:
001031 - Exhaust gas recirculation (EGR) potentiometer: Signal too low.
P0407 - 000 - -
Environmental conditions:
Error status: 01100000
Error priority: 2.
Error frequency: 52.
Mileage: 124,327 km
Time: 0.
Date: 2000.00.00
Time: 14:19:28

Environmental conditions:
Speed: 0 RPM.
Speed: 0.0 km/h
Last: 0.0%
Lambda: -19.1%
Air mass/Hub: 595.0 mg/H.
Air mass/Flow rate: 0.0 mg/H
Binary value: 00000000

001027 - Exhaust gas recirculation (EGR) valve (N18): Malfunction.
P0403 - 000 - - - Intermittent.
Environmental conditions:
Error status: 00100000
Error priority: 2.
Error frequency: 1.
Mileage: 124,440 km
Time: 0.
Date: 2000.00.00
Time: 22:13:29

Environmental conditions:
Speed: 1218 RPM.
Speed: 15.0 km/h
Key press ratio: 0.0%
Voltage: 14.14 V
Air mass/Hub: 210.0 mg/H.
Key press ratio: 0.0%
Binary value: 00000000

Readiness: 1 1 0 0 0

Saturday, March 14, 2009, 00:09:46:07974
VCDS Version: DRV 812.3
Data as of: 20090224.



'Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein.'
'Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein.'


Mode 07: Pending emissions-related faults.

Address 10 (Engine Control): 1 error found:
P0405 - Exhaust Gas Recirculation (EGR) Temperature Sensor (G98): Signal too low.

Address 1A (Transmission): No error codes found.


The exhaust gas recirculation valve has already been replaced three times, so that can probably be ruled out .
The vehicle is shaking violently and going into limp mode with excessive black smoke.
What should be the next steps to narrow down the error?
NO DPF (Diesel Particulate Filter) present!!!

Hello,

Was a complete throttle body module (!) replaced? If so, a broken cable or damage caused by rodents is not unlikely.

Best regards, Rainer.

Hello Rainer,

I also suspected that. Unfortunately, I could only trace the cable as far as the main cable bundle. Does it go directly to the MSG?
The throttle valve is still the old one, but the EGR valve located behind it is new.

I'd also like to check the wiring.

Over 300 km per day... not bad. Whoever drives 124,450 km in a year also has little time for visits to the workshop...

It's a taxi... and it's particularly frustrating because the car is always in the workshop for 1-2 days, and the problem isn't fixed .


EDIT:

Okay, I found the problem... the cable coming from the AGR valve, the one that plugs in on the right side, runs for about 5cm into a cable harness that goes down (behind the engine block). This harness has several guides with plastic holders. Some of these holders seem to be porous, and the cable was hanging loose and rubbing against them. This has probably been happening for a long time, as the protective corrugated tubing was worn through, and two cables are affected.
Cables were repaired --> everything is back to normal.

Thank you .