2.0 TDI AGR Valve: Faulty & Replacement Guide

Hello,

In my premium product, the mechanical component of the EGR valve failed after approximately 63,000 km.

The EGR valve consists of a type of throttle valve that is operated via a shaft and two sets of gears.

Ironically, the least stressed gear, which is located on the drive shaft of the actuator motor, is made of metal. The rest is made of plastic and suffers from tooth wear, even though the valve itself operates smoothly.
Clearly, the wear and tear is due to incorrect material selection or inadequate sizing.

- Is there an improved EGR valve with a metal wheel?
- Is 03G131501Q the latest revision level?
- Is there a free replacement available from the manufacturer of the premium product, as there appears to be an obvious design flaw?

Best regards, Rainer.

If this issue isn't properly addressed, you could end up with significant defects that a competent workshop would likely replace under warranty.
Oops... or the warranty has expired .

EZ 10/2007 = no warranty.

Hello Rainer.
Visit an AMAG dealer near you and request a goodwill gesture/favour.
Soweit ich weiss gibt es 70% auf das Material im 3. Year.
If you provide me with the vehicle identification number (VIN) and mileage, I can also check it for you.

Regards,
Sascha.

The cross-brother BMR received a new valve in 2008.
03G131501 to 03G131501P.

How did you notice the defect?

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

dieselmartin wrote:

How did you notice the defect?

Pmax ~ 35 horsepower

Fortunately, it's at least always "too."

@bakkano: Thanks, DM!

Best regards, Rainer.

No wonder with all the plastic . Wouldn't it be easier to disable the AGR (Active Grille Roller) via software?

T3Surfer wrote:

Wouldn't it be easier to disable the AGR (Automatic Gear Recognition) using software?

Yes. However, I often have many short trips in a row, and without the EGR system, this makes it difficult for the DPF to regenerate properly because the engine doesn't get up to temperature easily, and the exhaust gas temperature is also lower.

Best regards, Rainer.

Quote:

Yes. However, I often have many short trips in a row, and without the EGR system, it's not good for the DPF regeneration because the engine hardly gets warm enough, and the exhaust temperature is also lower.

Aha . That's why! I understand; it's the same with my car. If the EGR valve is disconnected, it barely warms up in city driving when it's below freezing. Short trips unfortunately ruin all sorts of things .

Hi Rainer, what did you do now, buy a new one or something? That's really annoying, isn't it ?

Hello,

I ordered the 03G131501Q part relatively cheaply from a general parts supplier instead of from the overpriced dealers. The cost was probably even lower than what Audi would charge with goodwill arrangements.
I'm going to check if the teeth are made of a more durable material or at least wider. It should arrive today.

Best regards, Rainer.

It's also cheap plastic junk, and that's on an A6...

Junk thing

It was probably possible to manufacture it even more cheaply .

matthiasTDI96 wrote:

It was probably possible to manufacture it even more cheaply

.

See SMC intake manifolds, SMC oil pans...

And the perverse thing is, you can justify it so nicely with "weight and thus fuel consumption reduction"... or rather, put a positive spin on it.

And what the SMC manifolds hold can be seen in the swirl flaps of the intake manifolds .

m;
also with a plastic funnel.

dieselmartin wrote:

See SMC intake manifolds, SMC oil pans... And what the SMC manifolds hold can be seen in the swirl flaps of the intake manifolds .

What is SMC? Does it stand for Sheet Metal Compound?