EGR fault

[Ray T6]

I have a 2016 T6 that I have had a nearly a year. It had the EGR previously replaced at 18000 miles by VW and is now just turned 40,000 and getting a high coolant loss 100ml in 12miles. Taken it to VW garage who said there is a massive internal coolant leak with the EGR and it needs replacing. I will go ahead and get this done but I am concerned what caused it? Could it just be the EGR Cooler didn't last long or might there be another fault causing it to fail?
Any ideas why it might be full of coolant and failed?

 

[DXX]

Which engine type?

 

[Ray T6]

Hi, the van is a T28 H-LN 1968cc TDI BMT 103bhp

 

[DXX]

I’ve stripped and cleaned an EGR valve / cooler from a 102, I didn’t see any reason why the cooler is susceptible to leakage. It’s a fairly well made round tube cooler unlike the unit used on a 204.
You don’t mention how many years since the last replacement but with just 22K miles service it’s worth going back to VW and attempt a warranty repair. Keep records, preferably emails and don’t give in.

 

[Ray T6]

Thanks for the idea, mine a 2016 model and VW customer services told me the EGR was changed in 2017 (Otherwise I wouldn't have know) at 18,000 miles so although not done many miles since, it was over 5 years ago so I think they're unlikely to cover it but I will ask. Yes keeping all records of any work done thanks.

 

[Dellmassive]

that's very low mileage per year . .

did it have the correct antifreeze ( pink colour?)

just wondering about internal corrosion from sitting about?

 

[Ray T6]

that's very low mileage per year . .

did it have the correct antifreeze ( pink colour?)

just wondering about internal corrosion from sitting about?

Yes first owner racked the mileage up to 18,000 then its just been a leisure vehicle since then and with Covid not used much. I bought the van in March 2022 and again its a leisure vehicle so I've only done 4000 miles in the last 10 months. VW have checked the coolant which all seems to be OK and yes Pink colour. G13 I believe.
I guess I'll only find out if its something else causing it once the EGR cooler is changed, hopefully that will sort it, if not I guess its then going to be further investigations

 

[Loz]

They can pressure test it and remove the front EGR pipe and see if it's full of coolant. Or as this guy does, run it with the pipe removed..

 

[DXX]

that's very low mileage per year . .

did it have the correct antifreeze ( pink colour?)

just wondering about internal corrosion from sitting about?

It’s all stainless steel including the gasket between the cooler and valve.

 

[Dellmassive]

They can pressure test it and remove the front EGR pipe and see if it's full of coolant. Or as this guy does, run it with the pipe removed..

Nice vid.

A supprising amount of coolant comes out.

 

[Deleted member 224]

Hi Guys
I need an EGR valve replacement, quick question....when they say EGR valve replacement do they mean the entire assembly? I am reading various things about EGR valve and then separately about EGR Cooler. Is it one unit? so that when they do the job it is both valve and cooler that are fixed?

 

[Noddy996]

Yes, it is all one unit @steve

 

[Deleted member 224]

good to know thanks, hopefully it will sort out the issues I've been having

 

[ThunderboltFMF]

They can pressure test it and remove the front EGR pipe and see if it's full of coolant. Or as this guy does, run it with the pipe removed..

Excellent shout there, always learning.

 

[Banjodinky]

Mines driving me nuts the EGR warning light comes on almost every day saying it’s not getting enough oxygen. The bus doesn’t drive any different and doesn’t go into any sort of limp mode . It’s a 66 plate 2.0 manual and has done 68000

 

[Ray T6]

How are you getting on with your EGR warning light any luck in getting it sorted?
After having VW replace my EGR and cooler in Dec 2022 it has run fine for nearly 7000 miles and 18 months but now the Orange engine warning light has come on. My simple diagnostics OBD11 shows fault P040100 and states Exhaust Gas recirculation - Flow insufficient. Is this likely to be the new EGR at fault so covered under the 2 year parts warranty?
Why might the gas recirculation flow be insufficient? ie What could be causing it?
My van is a 2016 T28 H-LN 1968cc TDI BMT 103bhp with a mileage of 47,700miles

I Have changed to using shell Vpower diesel and BP Premium for about 4 refills to help keep things clean in hope that it will help.
Does this warning light just go off if the problem clears?
If I clear the fault can I expect it to come straight back on or might it take a while for the insufficient flow to be detected again?

If anyone can shed any light on this that would be great as this is also driving me nuts!!!!
Thanks
Ray

 

[DXX]

Why might the gas recirculation flow be insufficient? ie What could be causing it?
My van is a 2016 T28 H-LN 1968cc TDI BMT 103bhp with a mileage of 47,700miles

I Have changed to using shell Vpower diesel and BP Premium for about 4 refills to help keep things clean in hope that it will help.

Fuel preference won’t make any difference before or after a fault develops.

It could be caused by one or more of the following.
1. Split or leaking EGR gas circuit, often a cracked pipe at the bellows, will be a strong smell of exhaust gases / soot stains on pipe. If so replace the pipe, there maybe an improved design pipe available.
2. EGR cooler fouled with carbon, the EGR has a finite life, it WILL block, it’s a consumable. You maybe at that point at 47K miles if you have many short journeys and / or high oil consumption. If so it needs renewing.
3. EGR control system, unlikely but not impossible.

 

[Ray T6]

Thanks, I'll take a look to see if its anything obvious from your comment above otherwise it'll be another visit to VW in Chelmsford again and hopefully it'll still be under warranty. If the EGR is a consumable then for me its a pretty expensive one as paid just over £1500 to VW 18months ago and having only done 7000 miles since I would have expected a lot more miles from it.
Cheers

 

[DXX]

After having VW replace my EGR and cooler in Dec 2022 it has run fine for nearly 7000 miles and 18 months

Somehow I missed that earlier! I’m almost 100% sure that the new EGR won’t be clogged at 7K miles, IF they renewed it.
Another possibility is that the pipes are fouled with carbon, there are different types of EGR used in Transporters, VW modified some pipes so that they don’t block with carbon so easily.

 

[Ray T6]

Well I guess that's good news if its unlikely to be the EGR clogged, I spoke to VW about the modified parts before they changed it and they said they would be using modified parts . Could it be DPF or would that give a different warning light?
Thanks