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2.0 TDI: EGR cleaned, won't start

 
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Heiner111
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Post24-07-2023, 19:19    Subject: 2.0 TDI: EGR cleaned, won't start Quote

Hello, it's about my A4 2.0 TDI with a BRD engine (16V, 170 hp) again. I'm actually quite embarrassed to say this, but it won't start anymore after I cleaned the AGR valve. Something like that shouldn't happen.
Weil er immer mal wieder ruckelte habe ich erstmalig das AGR bzw den Durchlaß daneben hinter der Drosselklappe gereinigt. War auch zu min 50% zugekokt. Beide Klappen sind (und waren wohl auch) gängig. Ich hatte nur die Kombi aus beiden Klappen ausgebaut, sonst nichts am Saugrohr etc. An beiden habe ich die Deckel vom Steller abgemacht und innen gereinigt, wobei es nur bei der Drosselklappe nötig war (innen wie üblich voller Öl). Dann wieder alles montiert - und nun juckelt er, zuckt nur manchmal wie bei Kraftstoffmangel, aber kommt nicht. War nie ein Problem. Fehlerspeicher MSG zeigt gar nichts, aber Readiness der AGR ist "fehlgeschlagen". However, the ignition was never on during the expansion process; therefore, this state must have occurred during the first attempt to start it.
For my understanding, it should still start, or have I misjudged something? I can't rule out that something might have been damaged in one of the valves, even though I made sure that the fine wires in the throttle valve actuator didn't cause a short circuit. However, from my perspective, the failure of both actuators shouldn't be the reason for it.
- If there was a problem with the EGR valve, it should still start without any issues. It only opens occasionally... Or is something being electronically blocked if there's a fault?
- The throttle valve is open when the ignition is on, and it feels completely open. With the screwdriver, I can insert it completely into the opening after removing the intake hose. So, that should also be ruled out as a cause.
- I haven't checked the throttle valve; it operates under vacuum anyway. However, it's difficult to inspect while the other two are still connected.
- What's puzzling me is that he's complaining about a "Readiness" issue, but there are no error codes in the diagnostic memory that could cause it or even trigger that message. Or does it have to be reset after every start? Probably not. If that were the case, it wouldn't pass the technical inspection (TÜV) right away...

Just to add some more information:
- The battery was brand new last week. It's not due to a lack of RPM or anything like that.
- I would have liked to run the diagnostic tests on both actuators using the actuator diagnostics function. However, this incredibly unintuitive sequential diagnosis of this control module cannot operate either of them. In my A5 (3.0), it works perfectly fine individually.

Does anyone have any ideas? Where might my mistake be?
Is there a classic pitfall that I might have missed?

Sure, here's the translation:

"Thank you in advance."


Translated on 09-07-2026, 23:36.
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Post24-07-2023, 19:33    Subject: 2.0 TDI: EGR cleaned, won't start Quote

Hello,

Did you forget to plug in the electrical connector for the throttle valve?
If applicable, make sure the throttle is open, disconnect the spark plug, and try to start it.

Okay, hier ist die Übersetzung des deutschen Texts ins Englische:

"Please provide the text you would like me to translate from German to English."

Best regards, Rainer.


Translated on 09-07-2026, 23:39.
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Heiner111
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Post27-07-2023, 19:20    Subject: solved Quote

Hello, the engine is running again.
@Rainer: Thanks for the tips.

I wanted to explicitly mention in my first post that I had also checked the position of both connectors, but then I forgot. However, this wouldn't really be relevant because the position of the AGR valve probably shouldn't noticeably affect starting, and the throttle valve is open anyway when it's not powered. Unless, of course, the return spring has broken, which I checked before while cleaning it.
Letztlich habe ich gemäß Rainer sicherheitshalber beide Stecker abgezogen und es einfach nochmal probiert. Nach mühseligem Juckeln (Dank an meine neue Batterie) zuckte er dann immer öfter und irgendwann kam er dann zäh. Habe kurz laufen lassen und dabei beide Stecker wieder montiert. Ein weiterer Versuch 10 min später war immer noch zäh, aber deutlich besser. Dann 1 km gefahren (mit Dreckfahne hinten raus, was er sonst so nie macht). NäcThe start was almost normal after that.
The next day, everything started up normally - and everything was fine.

I really hadn't done anything wrong. The only thing that was uncontrollable was the actuator diagnosis. I quickly went through the individual points because I wanted to see the (non-existent) control signal for the valves.
And I think something might be misconfigured or there's a problem with the messaging system. Wasn't there also an issue related to injection settings?


Translated on 09-07-2026, 23:41.
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Post27-07-2023, 21:14    Subject: 2.0 TDI: EGR cleaned, won't start Quote

icon_cool.gif

The engine does not have a throttle valve as a control element. I also suspect you might have another problem. Does it smoke when it's difficult to start? If so, it's likely not getting enough air.

Is the software in the engine control unit (ECU) original? You can mess things up or disable a lot of functions, and then errors might not be detected anymore.


Translated on 12-07-2026, 10:59.
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Post30-07-2023, 11:54    Subject: 2.0 TDI: EGR cleaned, won't start Quote

Hello again, the engine actually has another problem, but I don't think it's related to the previous issue. I will open a separate topic for that, as it seems to be a completely different problem.
"Should everything still be completely original, with no modifications or tuning."
He doesn't normally smoke when starting, and otherwise he hardly smokes at all except for the isolated incident last week. The air filter is almost new, the flaps are open, and I can't think of anything else that could restrict airflow (the area after the EGR valve was cleaned recently, but just before the problem started, as mentioned above).
Since then, I've driven it for a few days, and it starts up completely normally again.
Actually, I had that wrong in my memory: the actuator diagnosis doesn't involve any injection adjustment, as Rainer correctly pointed out. I probably mixed things up from memory; it was also clearly presented above only as a speculative question because I wasn't sure.
I think this problem has been resolved and won't happen again anytime soon. Thank you for the tips.


Translated on 12-07-2026, 11:01.
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