EGR problems/Noise from near egr valve - you tube clip

REBEL COUNTY1

Hi all,

My car is a diesel audi a4, 05 model, 2ltr, 140bhp, english import.

A pipe on the egr cooler broke a month ago and i replaced it with a s/h egr cooler.

Prior to the cooler breaking, at times, the engine would loose power. If i turned the ignition off and back on (while driving) the power would return. After the egr cooler was replaced the mechanic checked the engine light, that was on, and it read air flow meter fault. The vacum hose and ventilation hose had been burnt by the hot air coming from egr cooler (both also replaced) and mechanic said this may have caused air flow meter fault.

A week ago the engine light came on(no power dip) Engine readout said "manifold flap motor". (No power dip)

mechanic turned off the engine light. Then power started dipping and light back on. Read "thermoistat egr valve" and "egr valve fault". (Should note it did not read exactly "thermoistat" but something to that effect)

We turned off the light, quick spin. No engine light but read a fault of "egr valve".

The engine is making this exact noise (this is a clip from youtube, not my car but this is also an audi a4)
http://youtu.be/vtonIASQIag

My mechanic reckons change egr valve and see how it goes.

I wonder from reading up online with the faults "intake manifold flap motor" "thermoistat egr valve" and "egr valve" is it a build up of carb and does the intake manifold and egr valve need to be cleaned ??

would this explain the broken egr cooler as the pressure was too much on it?(blockage preventing free flow of air)

What is this noise that is being made near (or by) the egr valve??

Any advice is appreciated, I'm no expert and only trying to figure it out from what i read online! I should also say my mechanic will be willing to go along with whatever i suggest, he's as open to ideas as i am and isn't pretending to know exactly what the problem is.

Thanks

gebbel

I have the same car only remapped. Had to replace the EGR valve last year after similar issues to yours. It solved the problem.

I would say you should do the same,

brian_m

I have an A4 Tdi car that has suffered similar problem.The flap inside the egr valve is moved by a stepping motor with a plastic cogs mechanism. These can become worn and or break, that is what is most likely causing the clicking sound, you should be able to take of the black plastic cover on the end of the EGR valve and inspect the condition of the mechanism. A new valve should sort it:

http://www.micksgarage.com/engine-parts/egr-valves/audi/a4/a4-avant/2004-2008/

REBEL COUNTY1

Thanks for de advice. Id say ill change it alright. I took off the air cooler pipe today and there was a bit of oil liningthe walls of the cooler pipe and egr valve!! No build up of carb though! I srayed carb cleaner in it anyway but didnt improve anything (not that i thought it would)

Should there be a bit of oil lining the egr valve?

If theres no build up of carb what is actuallycausing the intermittent dip in power??

blade1

Why not blank off the egr?

REBEL COUNTY1

blade1 wrote: »

Why not blank off the egr?

What would that involve?

blade1

There are kits on ebay.
Car runs better without egr.
Lots of people do it( maybe not so much in Ireland)
Egr is only a balls anyway!
Try googling it for some more info.

REBEL COUNTY1

blade1 wrote: »

There are kits on ebay.
Car runs better without egr.
Lots of people do it( maybe not so much in Ireland)
Egr is only a balls anyway!
Try googling it for some more info.

Wilk do, cheers blade.

Anyone know anything about the oil lining inside the egr valve?

blade1

U said the car was losing power.
Was this just the car going into limp mode or would you think it was something else?

REBEL COUNTY1

blade1 wrote: »

U said the car was losing power.
Was this just the car going into limp mode or would you think it was something else?

It was a loss of power (like the turbo isnt kicking in) If i knocked the ignition off and on imediatley the power would be back, but tgen just die again.

Does that expalin it better? I dont know hat "limp mode" is

blade1

Limp is basically just to get u home when there is a fault.
It won't let the car rev high so no more damage is done.
Was there an light on saying ecp?

REBEL COUNTY1

blade1 wrote: »

Limp is basically just to get u home when there is a fault.
It won't let the car rev high so no more damage is done.
Was there an light on saying ecp?

No light on except engine light! Ya that sounds about right what happening, that its going into limp mode and out of it! Some sort of electrical fault? Would the fault in egr cause this?

blade1

Egr could but so could other things too!
you saw oil in the egr, yeah?
Not sure but I think oil sludge in these engines can cause various problems.
How often would the oil be changed?

REBEL COUNTY1

blade1 wrote: »

Egr could but so could other things too!
you saw oil in the egr, yeah?
Not sure but I think oil sludge in these engines can cause various problems.
How often would the oil be changed?

Oil changed every 10,000 miles. Think ill go ahead and change de egr. See how that works. From others posts similar difficulties has been fixed from it! Would just hate to change it and it still be giving trouble!

brian_m

the egr cooler pipe is usually quite carbon/sooty looking, not so sure about oil though.. bearings in your turbo may not be the best. Egr blanking is not as straight forward as an ebay kit, you will also need a remap from what I am aware. When my car had egr trouble it was also down on power, it just throws the whole system out including the electronic controlling of the turbo

REBEL COUNTY1

Thanks for all the advice. Changed the egr valve and seems to have sorted the problem!!

blade1

Nice one!