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EGR valve on Audi 2.7 tdi needs replacing

How long does it take a mechanic to replace the EGR valve on a 2008 Audi A4 tdi

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  • Audi Master
  • 15,478 Answers

The time is going to be about an hour and the rate is the standard shop rate for the area that you live in. That will be about 165 an hour. Cost for labor is going to be about 260

Posted on Feb 09, 2014

  • 4 more comments 
  • Anthony Page
    Anthony Page Feb 09, 2014

    Thanks, the job has now been started and has taken over 6 hours and still not completed. But the EGR is quite a big part (around 250 mm X 180 mm) and not easy to get at because it is buried under a maze of piping, etc., Even to my untrained eye it appears a big job and not likely to be completed in an hour, but at 6 hours and climbing it does seem that the time taken so far is excessive.

  • Brad Brown Feb 09, 2014

    Mechaincs that do this job on this make and model have an advantage of knowing the bolt size and locations and what needs to be moved and removed, there is a shop book that give estimated time and then there is real time, a shop bills estimated time and a mechanic tries to get real time so that there is a huge profit made.

  • Anthony Page
    Anthony Page Feb 09, 2014

    OK thanks again. The tricky bit for a non expert like me is that when they showed me all that needed to be taken off I have no idea if there was another less invasive way of proceeding, but I have now talked to two separate Audi techs from other areas and they are both in the range of 6-8 hours. The difficult bit now is that this job is obviously going to take 12 plus hours and so we may have to do a bit of negotiation around that time.

  • Brad Brown Feb 09, 2014

    If you are doing this yourself go to autozone.com and make a free account and then put in the vehicle information and then look at the free repair guides and it is like chiltons manuals and shows all. If they dont have the info you can access a paid service called ALLDATE and that will have it.

  • Brad Brown Feb 09, 2014

    ALLDATA is what I meant to type.

  • Anthony Page
    Anthony Page Feb 10, 2014

    Many thanks, I will follow that up.

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SOURCE: code P0406 egr valve faulty needs replaced

well,if you know how to install the egr valve,i recommend doing it youself because the part is NOT covered under dealer warranty.i have an 05 300 limited and had this work done.the total cost will be between $480 - $600 dollars at the dealership.if you know a competent mechanic,take it there instead.the part cost around $200 dollars.

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SOURCE: Core Support and Radiator Replacement , Audi A4 Quatro 1.8

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Audi a4 1.9tdi


Your car goes in "limp mode"!!!
If you scan the EDC-15P engine control unit with a VAG or KTS -BOSCH diagnosis tool you will find this:
"Fault code: P1557 - Turbo Boost pressure control exceeded"
You must try follows if you are able to do this:
1. Engine stopped and ignition switch off. Check all pneumatic connections and hoses between turbocharger actuator = pressure unit for boost-pressure control, boost-pressure control solenoid valve, vacuum reservoir, EGR control solenoid valve, intake-manifold flap solenoid valve, EGR valve with throttle - part of intake manifold. Also the vacuum connection between tandem pump and brake booster. If you find something wrong replace parts. If not go to step 2.
2. Extract the hose of the turbocharger actuator = pressure unit for boost-pressure control part of turbocharger. Instead of the original hose you must place another 1 meter long hose with the same inside diameter, and then you check to inspire yourself the air from the other one extremity of this hose. The mechanical connecting rod of the turbocharger actuator must have a smooth and whole motion. If you can do that with your mouth, then you must replace the boost-pressure control solenoid valve. If you can not reach this with your mouth, then you go to step 3.
3. This is the most difficult work. The problem is that the soot particles deposits inside the turbocharger plugging the variable nozzle geometry mechanism = adjustable vanes of the turbine. If the turbocharger actuator is not able to adjust the turbine vanes the charge air pressure increase too much and ECU (engine control unit) go in "limp mode" = engine protection software. As a result the "limp mode" engine still running until you turn the engine off (ignition switch off) and back on when the "limp mode" is deactivated, but the fault ("Fault code: P1557 - Turbo Boost pressure control exceeded") still remain in ECU memory !!!
4. You must be able to extract the turbo from the engine and then to disassemble the turbocharger, clean inside adjustable vanes mechanism and refit all.
It is some work to do here, but after that you will be full satisfied! NO MORE "LIMP MODE"!!!
--------------------------------------------------------------------------------------------------------------------------------------------
It is a certified solution. Last year in July I made this turbocharger cleaning on my car - 2000 Audi A4 1.9 TDI 116 HP. After 25000 km my car runs like an authentic AUDI 1.9 TDI.

Jun 03, 2008 | 2000 Audi A4

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