On the most recent Euro 6 2 litre engines fitted by VAG there’s a glitch in the ECU software which triggers an unrelated code pointing towards a DPF fault. This video will explain why this code is triggered.
This guy knows his stuff !! I would love the opportunity to work along side him and learn all this stuff .as a mechanic theses videos really help with problem cars ..and above all get the customer back on the road without too much fuss ..keep up the good work fella
I’ve been and Audi Tec for over 20 years. This is how real garages should diagnose, dib of the cap to you sir excellent work sir, you known your craft 👌🏻
Thanks for this video. Currently in the middle of replacing one on a audi b8.5. What a horrible job 🤦♂️ this vid really pointed me in the right direction in terms of removal to gain access to the cooler 👌👌
Thanks for the explanation. Getting this code every 150-200 miles or so. Car had a DFP clean and sensor replacement earlier in the year so wasn't sure why the code kept coming up. Cheers!
Fantastic to see somebody who knows their stuff! My 68 plate Octavia 1.6 tdi dgte has been throwing up this code and lighting up the EML now for 18 months. When it started lighting up it was just out of warranty as you point out. Strange thing is it has been running and regenerating fine. It's a real pain though, will be my last diesel car, imo they're not fit for purpose anymore.
Those heat shields on the bulkhead can be a pain in the ass on some cars,i had a 2005 megane rs225 2.0 petrol turbo,all i had to do was replace an aircon pipe at the rear of the bulkhead. Unfortunately the pipe was 'behind' that heatshield!!It's the fact it's shaped to the bulkhead,i had to try and pull it up and out!Let's just say it wasn't the same shape went it went back in,it took me ages!!it was a nightmare! Another great video!! :-)
I feel better now, having sold my 100,000 mile VW 1.2 litre 3 cylinder turbo Polo for spares or repair, it developed the same fault after already, 24,000 miles earlier, having had its EGR valve replaced at some expense. The engine is transverse on the Polo, with all the exhaust plumbing up against the engine bay bulkhead, no wonder the garage who agreed to do the job, said it was a nightmare job! Well done on the video, showing your analytical and logical approach to problem solving.
Yes definitely a great video,I had a scoda superb with a blockage in the cooler ,so replaced the unit and all working fine 🙂. Thanks for a well explained video
Brilliant Gary and thank you, also well done for tackling this awkward to access cooler, think I would have passed the job on!. Thanks again for sharing. Kind regards Jay
This is an interesting case. I’m surprised to see this much carbon after the DPF. Also a delta pressure sensor would have been a better design choice or at least a computer algorithm to only check DPF efficiency when the back pressure valve is in the fully open position. I suspect with the EGR commanded on you would not see a drop in the MAF reading due to the plugged cooler. Great video as always!
Excellent video and explanation of this nightmare system. Just did the same on an Audi A4 for a friend. I bet you didn't drop replacing the bolts as many times as i did.
Whoever garages before you had this car must be tyre place I think , first thing what we should check to diagnose any dpf/exhaust problem is check air path (egr is 1st suspect) . Good bud as always boss
Excellent video. Why are these “consumable” parts buried so deep in the engine? I see similar issues on other VAG/Skoda models. These parts are not cheap, but it’s the amount of labour that’s required that makes it so expensive to resolve. If anyone is replacing these make sure to use genuine / OEM parts, not worth the risk using cheaper alternatives with all the labour that goes into it.
A very good video with a good explanation of the EGR/DPF layout. One question though, the EGR cooler looks easily to clean as its a tubular heat exchanger but fitting a new one appears to be what everyone does. Is this because its so hard to get to or is there another reason?
That Code p2002 on Most Diesel cars post 2008 would be caused by a blocked or partially blocked DPF and would be related to a driving profile problem, and in most case it would involve DPF flushing fluid directly into the DPF lowering the engine oil in case of creep and a 60k round trip on the Motorway, so it could do a passive clean. However there are sometimes more esoteric causes for this and other problems that have common causes. That's why its worthwhile getting your car repaired by someone who has experience not just of the problem but how it may relate to your car specifically. Its a good explanation here of a ongoing problem allot of cars with SCR systems are experiencing.
Very informative and helpful for my current situation! I've had my Audi A5 Coupe 2.0 for about a year now and this fault has appeared. From your experience what would be the usual cost to expect with replacing this at a garage?
Very helpful and informative post. I'm in the trade myself and have a 2016 A4 diesel with 125k with exactly this issue, so although it's a high cost issue, it's still good to know that I can direct my spending into the right area to resolve so I can retail the vehicle correctly. Also could you give me a steer as to where I can locate a new cooler as I don't think trying to clean out is the right option as to want to take the risk of throwing a light back on. Many thanks, regards, Darren
Hi, we done a few of these at our garage now, we simply remove engine gearbox and front suspension in one unit saves a lot of time as it’s modular constructed made to be removed in one unit.
How did you loosen the EGR cooler bolts without removing the exhaust pipe? The lower bolt between the exhaust pipe and the cooler. I can't get past it with my tool with an extension...
One question, during the time the exhaust flap valv is closed where does the exhaust gas go as it cant stay circulating around all the time as the engine produces more and more gas??
Great video, thanks. I had my EGR cooler/Valve replaced (2014 Golf GTD CUNA) and driving back, 'Ping' EML again and same code P2002. God knows what it is now!
@@intelligentauto737 I'd changed the pressure sensor and this is the next thing. Tbh, looking at the old one it was due a change anyway but now, stumped! (I did have an egr fault too).
Give us a follow up from the customer ( did it solve the money light issue ) please, i love videos where the customer finally gets a car fixed after other garages fail. Great vid mate, keep it up.
Hi. I cleaned the particle filter and after a diagnosis I have the following error: P200300 - Particulate Trap Efficiency Below Threshold (Bank 2). Can you suggest to me what could be related to dpf? Thanks.
Hi , when or what condition makes the exhaust gas divert thru the cooler rather tham the dpf and straight out the exhaust? Second question , acetic acid, vingear will dissolve urea crystals. Tell me in crazy , cause crazy idea but why couldnt I use a dose of vinegar in place of adblue to clear out from time to time.
I have a 2017 Passat 2.0 TDI BiTurbo 240 bhp. 127k miles. I have that fault code when i scan with VCDS. However i don’t have the engine light coming on. I would never have known unless i scanned the car, any reason for this? I’m guessing i have the same problem? The car performs flawlessly. Should i ignore for now? What would happen if i don’t change the egr?
What calibrations and settings need to be done once everything is put back together please? Do you need to do a regen and calibrate anything at all? Thanks in advance.
I have the same code popping up on my 2017 Skoda Yeti SCR. These newer EA288 engines were supposed to cure the EGR problems by diverting the exhaust through the DPF prior. Trouble is, now with the addition of DEF we are now dealing with a whole new set of headaches. I have an older 2010 EA189 Yeti with 475,000 miles on the clock. Still on original DPF and only ever needed one EGR which was on the front of the engine and took 40 minutes to change.
Great video. Can you maybe tell me whats the real cause that the egr cooler gets clogged like that? I mean sure Ad Blue is one reason.. and how long does it take to get clogged like that again?
thank you . great video tutorials .one question. Has it ever happened to you on renault 1.6 dci biturbo error p2002 dpf efficiency below the threshold ..
Thanks ever so much for the explanation of this system. If the turbo actuator moves from 0-100, can the EGR still be clogged? It's a shame that my 6 year old Audi needs such an expensive repair.
The shop that replaced my cjaa's DPF never reconnected the tube running to the lower pressure EGR filter. I'm wondering if this was a mistake or an attempt to prevent this from happening again. But I'm under the impression the EGR system lowers temperatures of combustion and prolongs the life of the engine.
Hello Gary. Great video and good explanation. I do have a question. The egr difference pressure sensor G450 is placed to monitor the pressure difference over de lp egr. That's it's purpose. Also the ecu knows when it shuts the exhaust flap. At that moment the ecu sees that pressure is rising in g450 and g505 if egr cooler is blocked. Why doesn't it set a faultcode on egr pressure difference to high? That's why g450 is on the car.
I have the same issue my mechanic will change the egr cooler and my question is should I change egr valve also cause he said that there is no need he will try to clean it
Very interesting and informative, Do you know if the ASB 3.0 tdi engine has the same system. My wife's car has the same 2002 fault, but she does very few short journeys, we have had the car for 13 years and only twice has the dpf light turned on and each time just by driving in low gear for a while the light cleared. Now it is in limp mode with the glow plug light flashing and the 2002 code comes back as soon as it is deleted.
Yeh it’s becoming more common as these vehicles are coming out of warranty. This was from about a month ago. Over the years I’ve diagnosed this exact fault plenty of times but this is the first I’ve actually repaired, I look forward to your take on it.
Yes it’s becoming a major issue, dealers where replacing the coolers every week but are not seeing as many these days as warranties have ended, good video Gary,, believe it or not I actually done one on the exact same vehicle a few weeks back. It is straightforward but reassembling is slower then the stripping down.
I would of liked to of seen the DPF pressure sensor readings in either live data, scope or other meter measurements. A before and after would of been great. DPF’s block up for fun. We can’t assume that the EGR cooler is always the culprit. Due to the chemical reaction that takes place in a DPF, we have to be carful about our approach to cleaning. The EGR however does not use the same chemistry and can be cleaned many times. I accept though, this job is very labour intensive. It pays to replace with a quality new unit. Thanks for the video…
We took all this off the car recently, the EGR valve and cooler were incredibly clean, like new, but the second EGR was pretty dirty and it clogged some holes in the intercooler.
Im getting this on a 2016 A5 with 62K! , no loss of power, and everything seems fine. Except for every 150-200 miles the light comes back on. I have squirted some Wynns EGR cooler in there in an attempt to combat it off until i sell it. I doubt it will help "much". So far no light but suspect your video is bang on the money if it comes back. Im just going to remove the unit, use mr muscle oven cleaner and deep clean it all. Put it back.
Is it necessary to unplug fuel pipes? I’ve got the same problem to deal with. I am all ok woth removing and cleaning egr cooler but don’t have access to vag software to prime fuel system. Great video!
How many man hours for that pal? I do p0401 egr code by removing egr cooler on transporter t6 engines and cleaning with egr cleaner or if really bad ill just replace entrie assembly. This looks a tad worse of a job though!
See a lot of this as a misdiagnosis, given that EGR is monitored via delta pressure it's any wonder this happens. I have seen zero soot conent stored yet P2002 which inevitably leads to an EGR exam and it is totally clogged.
Nice explanation mate. That means if the egr valve is blocked theres no way a technician can tell by diagnostics if its a bloclage in dpf or just the egr valve thats blocked? Im no technician but im guessing there would be a difference in cost between egr and dpf repair isnt it?
Hello, I am opening the discussion with the following problem: I own a Leon 1.6 tdi, with 198,000 km, engine code CXXA, in which the oil level in the bathroom was increasing, around 1 liter above the maximum level after 5-6000 km traveled. After all the possible tests carried out, it was concluded by a service specialized in the repair of Delphi injection systems that the problem is with the injectors, that they lose at the nuts. I specify that before removing the injectors and checking them, the exhaust pipe was perfectly clean, without soot, as it happens with any Euro 6 diesel, the engine was working perfectly, with no warning lights on the dashboard. After checking, it was decided that one part of the injector must be completely repaired (??), and the others only require nuts and specific adjustments. After 2000 km from the intervention, a little smoke appeared only during short acceleration, and for a short period of time .I wouldn't have noticed the issue if the on-board engine light hadn't come on, accompanied by the error P200200-Diesel Particulate Filter Efficiency Below Threshold B1. In addition to that, the exhaust pipe also smoked. The engine did not limit, it fires as well as before the injector repair. The error can be deleted, but it reappears after 50-60 km. I returned to the service indicating the problem, and this time I was told that the problem is not with the injectors, but with the DPF, which is "broken", that is, it only retains the soot. Somehow I'm in the field, I deal with trucks, I work with the same systems but they're on a different scale, I replied that it can't be a broken DPF. They are euro2 systems that, if they work in optimal parameters, do not produce any soot. I still use injectors, only here he walked. I also attached a picture. I want to know if there is anyone here with the same problem and how they solved it in the end.
Hi, another excellent video. I have a 10 year old 2 litre diesel with the Peugot engine, going like a train. Thinking about buying a vw group 2 litre diesel, probably an Octavia. In your experience at what kind of mileage do you start to have problems with this engine?Could you also please include the mileage of the cars you are working on. Keep the videos coming, it is a pleasure to watch someone who knows what they are talking about.
If I remember correctly this car had about 35k miles on it, I’ve done others with varying mileage but it would seem the cars that are used in an urban environment are more likely to have this issue
Have a similar problem with Audi A4 Ultra Sport 2016 with ad blue. Car not losing power. Forced regen done but engine management light reappeared within 7 days. fault code is P200200. Sensors checked and all ok. Is this the same fault code as P2002? And will replacing EGR cooler solve the problem? Thanks
Hi. I have the same problem for my Audi a4 s-line 2017 avant, the code which appears on the computer is p200200. I just wondering if you solve the problem by replacing EGR cooler?
dear i changed the Exhaust the 2 sensors and egr valve i have toyota corolla verso 2005 and i still have the code p2002 and when i remove the code with OBd it will come back in 5 min and i lose power when i drive after the code show up i spend a lot of money what can i do to fix it
Hello, I have the same problem (p2002) with my Audi A4 B8 2015 allroad. We check the dpf and it is all OK. So I'm sure there is a EGR Cooler problem. Maybe you now if the (EGR OFF + remap) can fix the p2002 problem?? Thanks.
I'm curious what causes the cooler to plug up. Since it's mounted post DPF, all soot should've been captured in the trap. I tought the entire purpose of LP EGR was to have "cleaner" low oxygen air compared to tapping it off straight at the exhaust manifold. Big thanks for sharing your knowledge in these videos.
Would it not get coked up when it does a regen though? I'd assume the EGR stays closed during the process to limit how much passes through it. Either way, I shouldn't think what passes it by in that brief period would be enough to stick.
Brilliant video thank you for taking the time to upload. The reason I found this video is because I have the same problem - hoping you might be able to advise, diagnose, and repair. I have a 2016 A4 with the DETA engine, same p2002 code comes up every 150 miles or so after clearing with VCDS. No loss of power, mpg is still in the 55-65 range. DPF regens happen and Adblue consumption is about 10liters every 6months. I do about 400miles/week on the motorway, it has 93k on the clock. I stuck a boroscope down the intake hoping to get past the EGR valve to confirm a blockage in the EGR cooler, BUT instead the EGR flap motor was struggling to move, It was "dancing" almost like the gears are stripped. Could this be the cause of the p2002 code? Could also be a blocked cooler
Without seeing it it’s impossible for me to say if you have the same issue. All I can say is if the egr flap is sticking you need to ask why? If you’re local to me yes I can help with confirmed diagnosis and repair if necessary
