Audi A3 with EGR fault

The Audi A3 1.9 TDI presented an EGR error to our team, and the owner requested its removal to enhance throttle response.
We began by conducting a thorough diagnostic assessment to determine the root causes of the error and how best to address them.
Additionally, a stage 1 tuning file was requested to increase power, yielding an additional 35bhp and 90Nm of torque.
This tuning process not only enhances the vehicle’s performance but also improves fuel efficiency, making it a win-win for the owner.
The vehicle had previously undergone EGR removal at another remapping service; however, the engine light reappeared after merely 200 miles of operation, accompanied by a total loss of power.
After addressing the EGR issue, we were surprised to find that the previous service had not fully completed the necessary removals.
Our team employed advanced Autel diagnostic equipment to ascertain that the EGR was still malfunctioning.
This thorough approach allowed us to pinpoint ongoing issues that could have led to further complications down the line.
Following a smoke test on the vacuum lines associated with the EGR, we identified a split vacuum line that was causing further issues.
Despite our initial efforts, it became clear that the system still had residual faults that needed further investigation.
We successfully repaired the split line and cleared the fault codes; however, the engine light illuminated again after 15 minutes, indicating the same EGR fault.
This specialized remapping is crucial in cases where standard methods have failed to resolve persistent issues.
Consequently, it became necessary to utilize AlienTech for remapping the ECU.
Under these challenging conditions, we took extra precautions to ensure the integrity of the ECU during the remapping process.
Despite encountering challenges during the remapping process due to a new BCM and security bolts fitted to the ECU, we confirmed that the unit had not undergone prior remapping.
As a result, we were able to deliver a noticeable improvement in performance along with peace of mind for the customer.
After successfully removing the EGR from the ECU and uploading a stage 1 tuning file, the vehicle’s performance was optimized, resulting in a highly satisfied customer.