09 Jetta TDI P0401 (EGR insufficient flow)

Discussion in 'Mk5 VW Jetta, Sportwagen, and Audi A3 TDI forum' started by chadwick1979, Jul 8, 2012.

  1. chadwick1979

    chadwick1979 New Member

    Joined:
    Jul 7, 2012
    Messages:
    4
    Car:
    2009 Jetta TDI
    I have an intermittent P0401 (EGR insufficient flow) CEL; dealer stated on invoice that the EGR filter is clogged and starting to ingest particulate filter (DPF). Recommends to replace EGR filter ($500) and particulate filter ($3200), a $4000 repair.

    I checked the DPF values with VCDS and they looked fine for the vehicle mileage (99ml of ash volume, soot usually below 15g); already initiated a few active regens, which the passive regen are keeping the soot down. I'm thinking I might just have to replace the EGR filter only and that will take care of the CEL, which only comes on every 50-100 miles after clearing the code. The car runs and drives great with no loss in MPGs. Any suggestions would be much appreciated.

    Chad
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  2. Keithuk

    Keithuk Super Moderator

    Joined:
    Aug 29, 2010
    Messages:
    5,534
    Car:
    2010 Golf GTD (170) CBBB
    Location:
    Stoke on Trent, England
    Welcome to the forum Chad. welcometomyturbodies

    VAG Error Code: 16785
    EOBD II Error Code: P0401

    Fault Location:
    Exhaust Gas Recirculation (EGR) System - Insufficient Flow Detected

    Possible Cause:
    Malfunction Indicator Lamp (MIL)(K83) ON.
    Reduced Exhaust Gas Recirculation (EGR).
    Reduced Power Output/Engine running rough.
    Increased Emissions.

    Hose leak/blockage.
    Basic setting not carried out.
    Exhaust Gas Recirculation (EGR) Flow restricted/clogged.
    Exhaust Gas Recirculation (EGR) Valve stuck closed/leaking/faulty.
    Wiring and/or Connector(s) from/to Exhaust Gas Recirculation (EGR) Valve faulty.
    Exhaust Gas Recirculation (EGR) System faulty.

    Possible Solutions:
    Check/Clean Exhaust Gas Recirculation (EGR) System.
    Check/Replace Exhaust Gas Recirculation (EGR) Valve.
    Check Wiring and/or Connector(s) from/to Exhaust Gas Recirculation (EGR) Valve.

    As taken from my http://www.myturbodiesel.com/forum/f9/free-eobd-ii-error-codes-software-2919/

    I did a DPF check on mine a few weeks ago, I had 9ml ash volume.

    [​IMG]
  3. chadwick1979

    chadwick1979 New Member

    Joined:
    Jul 7, 2012
    Messages:
    4
    Car:
    2009 Jetta TDI
    Hi Keith,
    How many miles are on your vehicle? I'm betting with only 9ml of ash you probably have less than 15k on it.

    Thanks,
    Chad
  4. Keithuk

    Keithuk Super Moderator

    Joined:
    Aug 29, 2010
    Messages:
    5,534
    Car:
    2010 Golf GTD (170) CBBB
    Location:
    Stoke on Trent, England
    Its just turned 14k and I do 70% local running about but I do give it a blast up the motorway now and then just to keep it cleaned out.

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