Audi A5 EGR Failure Symptoms & Repair Tips

Had similar vehicle emissions issues with my 2013 Audi A4 last year. The symptoms match exactly what I experienced, rough idle, black exhaust smoke, and reduced power with higher fuel consumption. The check engine light triggered due to the EGR valve being completely stuck in an open position. The repair involved: Full diagnostic scan to confirm EGR fault codes, Removal and inspection of the EGR valve, Carbon cleaning of the valve and surrounding components, Installation of new EGR valve and gaskets, Resetting the engine management system This is considered a serious automotive repair as a malfunctioning EGR affects engine performance and emissions control. The recirculation system needs proper diagnosis since similar symptoms can come from other components like vacuum lines or the EGR cooler. Key things to verify during repair: Complete carbon cleaning of intake manifold, Testing of all related sensors, Proper valve cycling after installation, Clear documentation of fault codes, Test drive to confirm fix The repair resolved all symptoms and restored normal engine operation. Make sure to request detailed documentation of work performed and any warranty coverage on parts and labor.

Thanks for sharing your experience with the EGR valve repair. The symptoms and repair process sound very similar to what my Audi A5 went through. Quick question, do you remember roughly how much you paid for the complete fix? Also curious if youve had any emissions test issues or check engine warnings since the repair was done? Want to get an idea of the long-term reliability after this type of work.

The EGR valve repair on my A4 cost 355 Euro total, which included parts, labor and the complete carbon cleaning. Looking back, it was worth every cent since the fix resolved all the issues completely. After getting the exhaust gas recirculation system repaired, the car has performed flawlessly. Zero check engine lights or emissions test problems in the past year. The black smoke disappeared right after the repair, and fuel economy returned to normal levels. Something worth mentioning, the mechanic found the EGR valve was completely jammed with carbon deposits, which explained the rough running and poor performance. A thorough cleaning of the intake system during the repair helps prevent the issue from recurring. From my experience, once a faulty EGR valve is properly diagnosed and fixed, the repair tends to be very reliable long-term. Just make sure regular maintenance is kept up to prevent excessive carbon buildup in the future. The catalytic converter was also tested during the repair to ensure the emissions control system was working properly as a whole. Everything checked out fine, which was a relief since cat problems can be much more expensive to fix.

Thanks everyone for the detailed feedback. Just wanted to follow up and share my repair experience in case it helps others. Took my A5 to a new shop that specializes in emissions control systems. They confirmed the EGR valve failure through diagnostic testing. The final repair included replacing the valve, cleaning carbon deposits, and checking the catalytic converter. Total cost came to 420 Euro. The automotive repair process went smoothly. After the recirculation system was fixed, all the original symptoms disappeared, no more black smoke, rough running, or power loss. Fuel economy is back to normal and the check engine light has stayed off. Had it for 2 weeks now and the car runs like new. The shop provided full documentation of the work and a 12-month warranty on parts. Definitely relieved to have found an honest mechanic who did quality work at a fair price. Best decision was not going back to my previous shop. The extra research to find a reputable diesel engines specialist made all the difference in getting the job done right the first time.