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Thread: 2009 Passat 2.0 tdi - Engine Fault - Workshop! Limp mode in high revs/hills

  1. #1
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    2009 Passat 2.0 tdi - Engine Fault - Workshop! Limp mode in high revs/hills

    Hi all,

    I'm having trouble with my 2009 Passat 2.0 TDI, when trying to kick on a bit or getting up hills etc the car goes into limp mode and coil light flashing with the following message 'Engine fault - Workshop!' I can pull over and restart the engine and it goes away for a bit until the next time I accelerate too hard or try to kick on to get up a hill.

    I've had it at two garages now, the first weren't auto electrics specialists they admitted but they cleaned out the EGR valve and some other cleaning - no replacement parts. They suggested it was probably a turbo issue.

    Needless to say same issue occurred next day or driving so took it to different garage who plugged it in and were adamant that the turbo was fine and the EGR valve was actually seized open hence the faults. Replacement EGR at a cost of 350 as it was a VW part. The next day on my motorway drive to work the same issue happened again, returned to the mechanic who replaced the EGR. He took a good look around everything, confirmed that the fault codes were only pointing to the EGR, but that the engine was coked up to the eyeballs (thank you previous owner!) and the EGR valve had probably been out of action since I bought it, last August. He advised that he couldn't think of much else it could be and said a couple of runs up the motorway in 3rd/4th should do it and would clear out the carbon.

    Have been doing this a few times, had it up to 80mph in 4th on relatively flat motorway with no issues, but the same thing happens every time I get to a hill without much momentum it goes into limp mode again, or if I try and kick on a bit to overtake.

    Really puzzled by the whole thing, and I'm reluctant to continue shelling out money to garages to look for different causes!
    2009 Passat 2.0 TDI-CR

  2. #2
    Senior Member Gazwould's Avatar
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    The curse of the egr valve aka the Devil...

    Excellent for reducing NOx but sticking open it causes egr limp mode , cokes up egr , inlet manifold , more soot in the engine oil causing wear and cokes up the turbo makes it stick causing an overboost limp mode and the extra soot will also kill a dpf if fitted .

    Less power and less mpg .

    Many disadvantages to one advantage....

    Everyday is a egr and dpf day...

  3. #3
    Administrator Keithuk's Avatar
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    You need to get your motor scanned (preferably with VAG-COM\VCDS) for any error codes logged in the ecu and post them, that will save a lot of guessing.

    It could be a blocked EGR valve.

    Post moved to correct section.
    2010 Golf GTD (170) CBBB, 5 Door, Shadow Blue (P6/D5Q), Transmission Code: KXZ, Flat Tyre Indicator, Basic Protection Pack + VCDS.


  4. #4
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    Cheers for the replies. I'll get in touch with the mechanic again to see if he stored the codes otherwise I'll take it to be scanned again. The EGR valve should be fine as he replaced it when I had it in last week. The previous one that he took out had seized and wasn't working, apparently not for some time.
    2009 Passat 2.0 TDI-CR

  5. #5
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    hi did you get this problem sorted, my can same issue, and replaced erg and had exact same dealings with people.

    did you get sorted? if so whats the fix?

    thanks

  6. #6
    Administrator Crasher's Avatar
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    A failed turbo actuator or clogged turbo is also common, I diagnosed two in one day last week on this engine.
    2003 Skoda Octavia VRS Estate. APR 98RON remap, APR R1 diverter valve, Jetex exhaust, K&N panel filter, 7.5x18 Alutec Monstr wheels with 225/40 18 Uniroyal Rainsport 3 tyres.
    2006 Polo GTI 1.8T, APR 95RON remap
    1988 Golf 2 GTI 16 valve, 2.2 with Weber Alpha injection
    1983 Golf 1 GTI 8 valve, 2 litre with Eurospec racing 42/36 head
    1972 1302LS auto 1641cc conversion

    Vile Invention

    Dark was that day when Diesel conceived his grim engine that begot you, vile invention, more vicious, more criminal than the camera even, metallic monstrosity, bale and bane of our culture, chief woe of our Commonweal. How dare the Law prohibit hashish and heroin yet license your use, who inflate all weak inferior egos? Their addicts only do harm to their own lives: you poison the lungs of the innocent, your din dithers the peaceful, and on choked roads hundreds must daily die by chance-medley. Nimble technicians, surely you should hang your heads in shame. Your wit works mighty wonders, has landed men on the Moon, replaced brains by computers, and can smithy a "smart" bomb. It is a crying scandal that you cannot take the time or be bothered to build us, what sanity knows we need, an odorless and noiseless staid little electric brougham.

    W.H. Auden (1907-1973), A Curse:

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