VW Crafter EGR Valve Trouble: Black Smoke and Jerks

I had a very similar issue with my VW Transporter T5 2.0 TDI from 2012. As someone with moderate experience in automotive repair, I recognized these symptoms immediately since they match what you described. My diesel engine showed the same problems, rough idle, black smoke, and poor performance. The check engine light prompted me to visit my regular workshop. They performed a full diagnostic test which confirmed the EGR valve was stuck, causing improper exhaust gas recirculation. The repair took about 4 hours. They first cleaned the EGR system to rule out carbon buildup, but ultimately the valve needed replacement. Total cost was 355€ including parts and labor. Since the fix, fuel economy improved and the engine runs smoothly again. I also passed the next emissions test without issues. Before suggesting specific solutions, could you share: Build year of your Crafter, Engine size and type, Current mileage, Any recent repairs or maintenance, Specific error codes if you have them This information would help determine if your vacuum leak symptoms match my experience and whether the EGR valve is likely the root cause.

Thanks for sharing your experience. I had my vehicle serviced just last month, and my EGR issues started shortly after, with the same symptoms you described. The mechanic did try cleaning the EGR valve first, but the problem persisted. The vacuum leak symptoms disappeared after the catalytic converter and EGR valve were inspected properly. My mechanic used a smoke test to check the entire recirculation system, which revealed the real problem, a cracked vacuum line near the EGR valve. The initial diagnosis was wrong and could have led to unnecessary part replacements. For anyone facing similar issues, a proper smoke test before changing parts can save money and pinpoint the exact problem in the emissions system. Total repair cost was 180€ including new vacuum lines and labor. Much cheaper than a complete EGR valve replacement.

Thanks for the update on your Crafter repair. This is a great example of why proper diagnosis is crucial before replacing major components. I had a similar experience with my T5 where the initial symptoms pointed to EGR valve failure, but deeper testing revealed a different issue. Your case highlights how vacuum leaks can mimic EGR valve problems. The smoke test your mechanic performed is exactly what helped diagnose my vehicle too. A cracked vacuum line affects the entire exhaust gas recirculation system, causing those typical symptoms like rough idle and poor acceleration. For reference to others dealing with similar issues, here are key signs that might indicate vacuum leaks rather than a faulty EGR valve: Hissing sounds during acceleration, Inconsistent engine performance, Rough idle that varies with engine temperature, Check engine light related to lean condition codes The 180€ repair cost shows why proper diagnosis matters. My initial quote for EGR valve replacement was nearly double that amount. After learning from both our experiences, I always recommend a complete vacuum system inspection and smoke test before replacing costly components in the emissions system. Good call on sharing this follow-up about the actual fix. It might help others save money and avoid unnecessary repairs when troubleshooting similar symptoms.

The mechanic was right to perform that smoke test first, it saved me from an expensive and unnecessary EGR valve replacement. Just wanted to follow up that after fixing the cracked vacuum line, my Crafter has been running perfectly for several weeks now. The rough idle is completely gone and fuel consumption is back to normal. For others dealing with similar diesel engine symptoms, I strongly recommend insisting on thorough diagnostic testing before agreeing to replace major components. The check engine light can trigger for various reasons, and what seems like a faulty EGR valve might just be a simple vacuum leak. My total repair cost stayed at 180€, much better than the 600€ initially quoted for a full EGR replacement. The smoke test revealed the true problem quickly and the fix was straightforward. Looking back, I am glad I asked for opinions here before authorizing more extensive repairs to my emissions system. Most importantly, the catalytic converter and other expensive parts were perfectly fine, it was just that small cracked line causing all the trouble. Regular maintenance and proper diagnosis really do make a difference in automotive repair costs.