Mk3 Jetta EGR Solenoid (N18) Fix - P1403

Discussion in 'VW Mk3 Jetta, Passat TDI and other/older diesels' started by Highland James, Apr 28, 2017.

  1. Highland James

    Highland James New Member

    Apr 28, 2017
    98 Jetta TDI Mk3 AHU
    Grey Highlands Ontario
    Hi all, first ever post, want to try to give a little back to the team that gave me some great fix info. Going to put this in bullets for ease of typing/reading.
    -Issue: low power - thought was constant, no CEL
    -Bought an OBD dongle and tried Torque Lite - got me the P1403 code
    -Upgraded to Torque Pro to monitor EGR Commanded vs Actual
    -Alas! These two aren't among the sensors reported by my ECU...
    -Read a bunch, resigned myself to having to clean the intake manifold/EGR
    -Realized at this point I was dealing with limp mode not constant low power, not sure if my dash CEL is out but it didn't come on for the P1403 code stored in the ECU.
    -Inspected and found little intake buildup, picked checking the solenoid before the EGR valve based on this
    -Checked resistance - 17 ohms (~800mA, seemed about right)
    -Checked with external 12V connection, could hear/feel it was moving at least somewhat
    -Disconnected vacuum supply hose near the injectors and the output hose at the EGR end
    -Wasn't sure if vacuum was transmitted when the solenoid is activated or deactivated - fired it with 12V and tried to suck air through from the supply hose - no-go in both cases (no vacuum to EGR!)
    -2x 10mm nuts to remove the soenoid

    *Solenoid Repair
    Where I live my options were: PartsSource-$350, Davenport-$230 or mailorder from RockAuto-$120 (all approx), so . . .
    At this point I'm going to apologize for no pics, occurred to me near the end of the job, I'll do better next time!
    The solenoid is two halves; the big blocky coil end and the round end with two of the connections (supply and load/EGR)
    Each of these halves has a round flange, and these two flanges mate together and are held by the metal crimp ring
    Pry the crimp ring open with a small flat screwdriver on the coil side, try to damage as little as possible, until it can be removed
    Separate the two halves, I tried blowing through the vacuum supply port but it was plugged
    Inside the solenoid the vacuum supply port comes out the end of a small diameter brass tube in the centre - the end of this tiny tube was visibly plugged
    I started with a #70 and worked up to a #62 drill to clean out the tube; due to the small diameter not much air moves through but enough to notice!
    Reassemble components and work metal crimp ring back into position
    I used two blocks that were taller than the ports end; flip the unit over (ports end down), rest the 'shoulders' with the crimp ring on the blocks and clamp down to a surface - this pushes and holds the crimp ring in position
    Use whatever pliers will reach to re-crimp the ring back under the coil-end flange so the unit will remain together
    All done - no codes and again have that full 90HP to throw me back into the seat : ))

    In all sincerity, many thanks to those who spent countless hours adding to this great site, thanks to you all I'm significantly deisel-smarter now than I was before.

  2. Keithuk

    Keithuk Super Moderator

    Aug 29, 2010
    2010 Golf GTD (170) CBBB
    Stoke on Trent, England
    VAG Error Code: 17811/005123

    EOBD II Error Code: P1403

    Fault Location:
    Exhaust Gas Recirculation (EGR) System - Regulation/Flow Deviation

    Possible Cause:
    Exhaust Gas Recirculation (EGR) faulty.
    Exhaust Gas Recirculation (EGR) Valve (N18) faulty.

    Possible Solutions:
    Check Exhaust Gas Recirculation (EGR).
    Check Exhaust Gas Recirculation (EGR) Valve (N18).
    Perform Output Test.

    As taken from my new Free EOBD II Error Codes software

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