SI 0100

For technical personnel only!

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Troubleshooting in exhaust gas recirculation system

Complaint Potential causes Remedies
Caused by EGR valve
• Irregular idling
• General: Coked/stuck EGR valve • Check engine controls
• Jerking
- Poor, inadequate combustion • Check software update of engine control unit
• Insufficient engine power
- Engine management fault • Avoid frequent short-distance drives
• Limp-home operation
- Frequent short-distance drives • Replace valve
• MIL lights up/error code set
- Leaks in vacuum system
• Insufficient engine power in
lower rpm range or in cold
• Defective solenoid valves • Check function, electrical actuation and
run (Otto)
• Malfunctions in vacuum system tightness of vacuum system
• Insufficient engine power in
See below: "Vacuum system"
upper rpm range (diesel)
• High oil content in intake or charge air: • Check oil separator, engine exhaust valve
- Malfunctions in crankcase ventilation • Check pistons, piston rings, cylinders, valve
- Engine oil level too high stem seals and/or guides for wear
- Low-quality engine oil • Check turbochargers for clogged oil return line
- Worn valve stem seal or guides • Change of oil and oil filter replacement
(by professional)

• Air mass sensor signal/other sensor signal • Check sensors for set-point values,
defective replace if necessary

• P0401 "Flow rate too low" • EGR valve does not open or is not actuated • Check connectors and actuation
• P0103 "Air mass too high" • EGR system has been shut down (the vehicle no
longer complies with the ABE!)

• P0402 "Flow rate too high" • EGR valve does not close/remains permanently open • Replace EGR valve
• P0102 "Air mass too low" • Uncontrolled, permanent exhaust gas recirculation • Check connectors and actuation

• EGR valve has temperature • Incorrect actuation • Replace EGR valve

damage, visible discolouration, • Exhaust gas back pressure too high • Check actuator of EGR valve
initial fusing (Otto) • Blow-off valve of turbocharger does not open • Check exhaust gas back pressure
• Check blow-off valve of turbocharger
("waste-gate") and its actuation

• New EGR valve, inoperative • New EGR valve has not been adapted • Conduct a basic setting of EGR valve
• High idling after installation using the engine tester
Caused by vacuum system/solenoid valves
• Engine "chattering"
• Defective hoses (porous, damaged by marten bites) • In the event of damage, check the tightness
• Engine misfires
• Leaking connectors on pneumatic valves of all components in the vacuum system and
• Limp-home operation
• Leaking non-return valves/vacuum reservoir replace defective part
• Decreasing braking
• Defective/porous diaphragms or seals on
performance
pneumatic actuators
• Leaks in intake manifold
© MS Motor Service International GmbH – 0509 EN

Caused by air mass sensor

• P0401 "Flow rate too low" • Air mass sensor damaged/dirty due to • Avoid any intake of water and particles
• Black smoke - Dirt particles in intake air into intake air system
• Inadequate engine - Leaks in intake air system, splash water
performance - Contamination during air filter replacement
• Limp-home operation - Clogged air filters
- Oil-moistened sports air filters

• Damage to turbocharger • Check turbocharger

EGR = Exhaust gas recirculation; MIL = Malfunction Indicator Lamp

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