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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.
    "I disapprove of what you say, but I will defend to the death your right to say it"

    Evelyn Beatrice Hall (28 September 1868 13 April 1956)

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