DIY EGR Valve Cleaning on 7P V6 TDI Touareg

Caesar · Aug 19, 2016

Hi all,

I know there are plenty of video tutorial available on youtube showing how to clean EGR on older Touareg... But I couldn't find any info on how to clean it on the 2nd generation (>2011) Touareg. The EGR on the newer touareg seems different... Anyway, i'm thinking of removing the EGR valve out and clean it along with the intake with Liqui Moly Pro-line intake system cleaner diesel. But i'm worry that it is not gonna be a walk in the park, as i thought. Could any one of you whom has did it yourself shed me some lights on this?

For your info, below is a snippet of my scan result from VCDS I did this morning.

Friday,19,August,2016,09:51:12:51960
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64(VMWare)
VCDS Version 16.8.0.3
Data version: 20160803 DS255
Ross-Tech: Home

VIN: WVGZZZ7PZBD029948 License Plate:
Mileage: 62343km-38738mi Repair Order:

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------

Chassis Type: 7P (7P6)
Scan: 01 02 03 05 08 09 0E 10 15 16 17 19 22 28 32 34 36 42 46 47
52 53 55 56 5F 62 6C 72

VIN: WVGZZZ7PZBD029948 Mileage: 62343km-38738miles

01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
0E-Media Player 1 -- Status: OK 0000
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
22-AWD -- Status: OK 0000
28-HVAC, Rear -- Status: OK 0000
32-Differential Locks -- Status: OK 0000
34-Level Control -- Status: OK 0000
36-Seat Mem. Drvr -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: OK 0000
55-Headlight Range -- Status: OK 0000
56-Radio -- Status: OK 0000
5F-Information Electr. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
6C-Back-up Cam. -- Status: Malfunction 0010
72-Door, Rear Right -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine (J623-CASA) Labels: 059-907-401-V2.clb
Part No SW: 7P0 907 401 B HW: 7P0 907 401
Component: 3.0TDI EDC17 H17 0006
Revision: 51H17---
Coding: 296A0012232E00000000
Shop #: WSC 31414 790 00001
ASAM Dataset: EV_ECM30TDI0117P0907401B 001006
ROD: EV_ECM30TDI0117P0907311A.rod
VCID: 2E59036E71DDBD3202-807B

1 Fault Found:
4807 - EGR System
P0401 00 [101] - Insufficient Flow
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 62335 km
Date: 2016.08.19
Time: 08:05:06

Engine speed: 1652.00 /min
Normed load value: 42.7 %
Vehicle speed: 69 km/h
Coolant temperature: 71 °C
Intake air temperature: 30 °C
Ambient air pressure: 1000 mbar
Voltage terminal 30: 14.240 V
Unlearning counter according OBD: 40
Mean injection quantity: 14.49 mg/stroke
Control Module temperature: 39.3 °C
EGR_governor_deviation: -243.4 mg/stroke
Inj Ctl q Curr: 14.61 mg/stroke
Standardised airflow ratio: 1.1537
Air_Flow_Rate_from_Mass_Air_Flow_Sensor_kg_h: 162.6 kg/h
Actual charge pressure: 1225 hPa

Readiness: 0 0 0 0 0

sarbmihai · May 10, 2018

how did you resolved?

dlysnes · Jun 7, 2019

Hi
Did you succeed in this? Looking at the same myself, but I know the process of removing the valve and cooler(s) is very messy..

/D

dlysnes · Jul 27, 2019

In case anyone want to do the same job:
I just replaced EGR valve on my 2011 7P5 V6 tdi Touareg. Based on many posts and talks to workshop it was said to be a massive operation. However I did it within the hour. Unfortunately the old EGR valve didn't look too bad, but hey; I now have a spare one ?
I also got the P0401 warning with EGR flow too low. Found a good price on pierburg valve and started working.
1. Remove the sensor on the top/back of egr with 2 vacuum hoses on it
2. Unscrew the 3 screws on the egr
Actually, that's it. The trouble is to losen the valve. I found out that I can use a baggage strap around it, attach a hammer in the other end, and then yank it out. It will losen ?

After replacing it the light still came on. So I started troubleshooting further. First I tried steaming it. It worked for a while, but came back. In other words, something is clogged. The steaming was very easy: while engine is running, remove the big tube front left just before the intake valve and put in the steaming end of a wallpaper removal steamer. Let it run until steamer is empty. Google it, pretty cool procedure.
I then suspected the pipe from egr to the intake. I removed it and cleaned it using different cleaners and also burner. Then I saw how the exhaust enters the intake manifold from that pipe: there's a narrow gap in the bottom of manifold just behind the valve. Easily gets clogged. Cleaned it out, and will now go for a test drive.

Esset_89 · May 13, 2021

dlysnes said:
In case anyone want to do the same job:
I just replaced EGR valve on my 2011 7P5 V6 tdi Touareg. Based on many posts and talks to workshop it was said to be a massive operation. However I did it within the hour. Unfortunately the old EGR valve didn't look too bad, but hey; I now have a spare one ?
I also got the P0401 warning with EGR flow too low. Found a good price on pierburg valve and started working.
1. Remove the sensor on the top/back of egr with 2 vacuum hoses on it
2. Unscrew the 3 screws on the egr
Actually, that's it. The trouble is to losen the valve. I found out that I can use a baggage strap around it, attach a hammer in the other end, and then yank it out. It will losen ?

After replacing it the light still came on. So I started troubleshooting further. First I tried steaming it. It worked for a while, but came back. In other words, something is clogged. The steaming was very easy: while engine is running, remove the big tube front left just before the intake valve and put in the steaming end of a wallpaper removal steamer. Let it run until steamer is empty. Google it, pretty cool procedure.
I then suspected the pipe from egr to the intake. I removed it and cleaned it using different cleaners and also burner. Then I saw how the exhaust enters the intake manifold from that pipe: there's a narrow gap in the bottom of manifold just behind the valve. Easily gets clogged. Cleaned it out, and will now go for a test drive.

Sucess?

DIY EGR Valve Cleaning on 7P V6 TDI Touareg

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