EGR valve cleaning on VAG CR TDI engine

[VeeFource]

Hi All,

So I've got the dreaded P0403 code on my Seat Ibiza FR and having done some research it seems more than likely the EGR valve has become bunged up. There's lots of info about how to clean the valves on PD engines which are mostly at the front on the intake manifold and so very easy to get to. However it seems the CR engine's is mounted on the back though I can't seem to find any more info on this, but it's apparently a 4.5 hour job to get to (and that's by someone who knows the car!) which sounds a nightmare.

Has anyone attempted this job themselves and if so what's involved? Is there a guide I've not managed to find on the net?

Thanks in advance :-)

[jjones]

wynns make an egr cleaner spray you fire into the air intake, might be worth a couple of tins before committing to anything else.

[anonymous-user]

jjones said:

wynns make an egr cleaner spray you fire into the air intake, might be worth a couple of tins before committing to anything else.

After cleaning the egr on a 1.9 pd I suggest that any spray solution will clean less than 5% of the st out. Mine wasn't particularly bad but still required 30 mins with a screw driver, carb cleaner and cloth. I don't think any spray that the engine can handle through the manifold will do much good.

Sorry I'm not much more help but IMO, forget a spray and physically remove it. Remember that the manifold is probably fully bunged up too.

[redtwin]

I wouldn't use a spray either. Even if there was one that was effective enough you wouldn't want the engine ingesting all the crud, especially if a largish chunk were to come loose. Dread to think of what that could do to the valves if chunks got lodged in a valve seats etc.

[VeeFource]

Yeah don't think I'm up for the spray idea, thanks for the input anyway though.

Seems there's no Haynes manuals for the mk5 Ibiza yet either, dohhh :-(

[redtwin]

Are there no DIY guides on the many VAG forums?.

[VeeFource]

redtwin said:

Are there no DIY guides on the many VAG forums?.

As mentioned in my first post, there seems to be a fair few on the PD engines, but I can't seem to find any for the CR or even pictures of exactly where the valve now is.

[Drive Blind]

VeeFource said:

Seems there's no Haynes manuals for the mk5 Ibiza yet either, dohhh :-(

There is a Skoda Octavia diesel haynes manual currently available that covers the CR engine and there is a Golf one due out soon which will also cover the CR engine.

might be worth buying one of them?

[anonymous-user]

Can't you just trace the piping. Surely it is pretty close to or next to the manifold. Can you out sm pictures up?

[anonymous-user]

Is it a 2.0 CR engine?

[George111]

I don't know about that engine specifically but the best approach is usually to take the manifold, valve and all associated pipework off the engine and clean with paraffin. It's not a pleasant task but well worth doing.

[VeeFource]

Topbox said:

Can't you just trace the piping. Surely it is pretty close to or next to the manifold. Can you out sm pictures up?

It's difficult just because there's so much piping everywhere and also the EGR pipe which leads to the manifold disappears into the cylinder head only to reappear the other side and God only knows what's between, I just hope the EGR valve doesn't happen in there as I've been working at getting the cooler assembly off the back of the engine given it looks a more likely suspect. It has the cooler valve on it but also another part which has the wiring loom typical with all recent VW EGRs so I'm hoping that's the culprit.

The biggest pain has been access apart from anything. And now the assembly's free, getting it out is the next problem as it's obstructed by the DPF, turbo oil pipe and a rigid cooling pipe which disappears behind a load of other bits which could all have to come out making it a nightmare to remove. The only way I'm going to be able to get it out without disturbing the offending cooling pipe and turbo pipe is by unclamping the DPF from the turbo to get enough room to split the EGR/cooler assembly in situ. Though I've a suspicion this may only be possible if you're lucky enough for each arm to have 3 elbows, but I'll keep you all posted.

Topbox said:

Is it a 2.0 CR engine?

Yup, it's the 143PS variant. Though mine is currently 0PS as it stands.

[Rick101]

I have CR Octavia.

I had the egr cooler fail which is at the rear of engine and was a £700 job.

I think the egr valve is at the front and relatively easy to access.

[Rich_W]

It's on the back of the engine.

4.5 hours IF you have access to the underside of the car. Even longer/impossible if you don't. VERY labour intensive especially if you aren't a pro. DPF and Oil pipes have to be detached for example.

I feel for you, but I'd be sucking it up and getting Seat to do the work. Maybe ask about goodwill contribution from Seat themselves if the car has FSH

[VeeFource]

Rich_W said:

It's on the back of the engine.

4.5 hours IF you have access to the underside of the car. Even longer/impossible if you don't. VERY labour intensive especially if you aren't a pro. DPF and Oil pipes have to be detached for example.

I feel for you, but I'd be sucking it up and getting Seat to do the work. Maybe ask about goodwill contribution from Seat themselves if the car has FSH

Good to know, thanks Rich_W! I take it it's part of the cooler assembly and it's the turbo feed oil pipe you're referring to?

I have the car on stands so I've got access to the underside and have detached everything from the cooler assembly. The only problem now is getting the swine out, not helped by the fact I'm currently working outside in the gales. I'm attempting to split it in situ but I think the real problem will be trying to reassemble it in situ after it's been cleaned. I may have to face facts that the turbo feed pipe needs to come out but I'm worried about the turbo not having oil when it's all reassembled, is this likely to be an issue?

[liner33]

Out of interest how many miles has it done

My CR 2.0 Superb is coming up for 75k and im thinking of a DPF, egr work this year , pre-emptive I hope

[VeeFource]

liner33 said:

Out of interest how many miles has it done

My CR 2.0 Superb is coming up for 75k and im thinking of a DPF, egr work this year , pre-emptive I hope

Well here's the shocking thing... it's only done 32k! I've read that the computer is a bit over sensitive for VAG cars of around this age (2010) and there was a software patch apparently that corrects this. However when I started this job I was of the mindset that it's probably best for it to be over cautious and I can rely on that so I don't need to be pre-emptive. However that was before I realised how much work's involved so in retrospect I should have just gone to the stealership to update the car with the patch (but then that's assuming it hasn't been already).

Normally I'm quite happy to work on my cars as I like to learn what's underneath and how to deal with issues when they arise. But then with the weather being so horrendous working on it is fairly painful and I don't fancy getting to work on the motorcycle in this either which is what I normally use when working on the car.

[anonymous-user]

Good luck. Sounds like a pain in the ass.

[Rovinghawk]

Rich_W said:

It's on the back of the engine.

4.5 hours IF you have access to the underside of the car. Even longer/impossible if you don't. VERY labour intensive especially if you aren't a pro. DPF and Oil pipes have to be detached for example.

I feel for you, but I'd be sucking it up and getting Seat to do the work. Maybe ask about goodwill contribution from Seat themselves if the car has FSH

Puts fuel economy vs petrol cars into perspective, doesn't it?

Good luck, however you deal with it.

[liner33]

Rovinghawk said:

Puts fuel economy vs petrol cars into perspective, doesn't it?

Good luck, however you deal with it.

People alway pick up on the exceptions , 2.0l vag petrols aren't without their issues and after 75k in mine I'm ££££'s in buying a diesel instead of a petrol even if it cost £500 to sort (not that mine has issues)