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Cleaning the EGR Valve
Published by Aircooledbug
29-01-2009
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Cleaning the EGR Valve

Cleaning the EGR Valve.

Tools needed:
10mm Spanner or 10mm Socket Set
13mm Spanner
5&6mm Hex Key
5mm Torx Key
Long nosed pliers
Small Wire Brush (sort you use to clean spark plugs)
Cloth
Patience!
And finally a nice cup of tea!

Its important before doing this task to disconnect the batteries Negative terminal. There is a risk of catching the Glowplug control unit and putting a short across it with hand tools blowing the fuse or damaging the control unit. Obviously you will need your radio keycode (if after market head unit is fitted) and the ability to re-set the clock


First things first is to remove the engine cover by the two 10mm bolts at the bottom. Then on to removing the 90 degree corragated pipe, first I would slacken the two 10mm hex bolts, then the two 10mm bolts (easier to use the socket set). Once slackened becareful of the metal seals at each end of the pipe. Once removed the pipe should easy come away, then your left with the removal of the EGR valve itself. On the left is a cable, remove this by slackening the yellow clip then pull off. Then you will see two gold coloured bolt heads and there is a third underneath the bolt on the left, undo these three with a 13mm spanner, they are quite long so dont worry about these falling out. Then you will notice a bracket that holds the valve to the manifold come loose whilst removing the bolts. Remove that with the three bolts. Then the EGR valve will stand on its own being held by another pipe below it. I removed this pipe too. If you follow this pipe down you will see it being held by a single 5mm bolt with a support bracket, undo this and the pipe will come free. The pipe will need a good clean, mine was clogged up.

Now to the EGR valve, you will have the valve and the pipe, take the pipe off, its held like the other pipe, 6mm bolts x2 then the metal seal. Once removed clean the pipe. I split the EGR valve in halve to clean the metal end and wow looked like a chimney from a 1800's house! Remove the four torx screws. On the mechanical end you will be able to push the valve to break free the crap thats inside. Blow out all the crap and clean it all the best you can with the wire brush and cloth. Then on the other piece you will see a little pin, use the wire brush to clean this, it was unbelievable seeing all the crap that came out of it! Then using long nose pliers gently pull the pin out to release more of the crap inside. Once all cleaned its time to put it all back together, remember to clean the spacer that was in between the to parts of the EGR valve. Once back together, this is were the fun begins!! Don't put the pipe back on the valve, put it back on too the engine were you loosened the single 5mm bolt, this took me 20 minutes! Finally once the bolt is in tighten up making sure the pipe is at the right angle and sitting in the right place! If your happy with were it sits then re-attach the EGR valve back to the manifold using the bracket and three golden looking bolts. Once these are tightened you need to attatch the pipe to the EGR valve to the (underneath) REMEMBER THE METAL SEAL!! Now when thats done, lucky you, this took me ages to do! Now re-attach the wire to the left and fit back on the 90 degree pipe and REMEMBER TO FIT THE METAL SEALS! and then the engine cover. JOB DONE!!

Take the car for a good run, not 5 minutes, im talking a good 20-30 minute drive, to justify if the work you have done has come to good use!

If not, then back to the drawing board!

Pictures below to give a better description.

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Thanks gren, scarlet_man, Journeyman, willeywilson, alexh365 and 2 others thanked for this post
Likes webby1981, widowmaker130, gren liked this post
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Old 29-01-2009   #1
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Re: Cleaning the EGR Valve

More Picture...
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Thanks scarlet_man thanked for this post
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Old 29-01-2009   #2
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Re: Cleaning the EGR Valve

Damn, sorry two more...

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Old 30-01-2009   #3
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Re: Cleaning the EGR Valve

great guide matey will come in very use full to us M-jet ers
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Old 28-04-2009   #4
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Re: Cleaning the EGR Valve

great guide Lee, just followed this to the letter and did mine, took me about an hour and half, insane the **** that came out
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Old 22-12-2009   #5
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Thumbs up Re: Cleaning the EGR Valve

Hi,
great article, a real help with sorting the EGR valve on my 1.9JTD Doblo.
A couple of points i thought might be of extra help.
After cleaning the soot out of the mechanical half of the valve the piston would not move by hand so i had to use some GT85 spray lube and apply some force. Resting the body on the floor (protected by a bit of carpet) i used a brass bar on the end of the valve and pressed downwards. Hurray, some movement, more spray and gentle force and the piston became free enough to move by hand. Soaked the body in some degreaser and the piston was free to slide easily with finger pressure.
Cleaned the rest as per the article.
I found access to the bolt on the bottem pipe a real problem. The allen bolt head was facing downwards and access was between cooling hoses which allowed about 1/4 of a turn max. It took me ages to undo this.
When i refitted it i flipped the clamp 90 degrees so the bolt head could be accessed from above.
My 11 year old lad was a real help holding the pipe in place while i refitted the clamp.
Overall i found access to the bolts tight, either to get to or for spanner movement, longer arms smaller hands and long fingers would be a great addition to the tool list.
The car is now back to it's 'sporty' self, success.
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Old 27-01-2010   #6
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Re: Cleaning the EGR Valve

anyone got picture of egr valve on ducato so i can locate it? thanks
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Old 27-01-2010   #7
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Re: Cleaning the EGR Valve

Quote Originally Posted by chug42 View Post
anyone got picture of egr valve on ducato so i can locate it? thanks
some dont have valve and some are motor driven dependent on van...you give no details (ask in ducato section)
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Old 27-01-2010   #8
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Re: Cleaning the EGR Valve

I always renew the metal gaskets and fit one swirl type
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Old 31-01-2010   #9
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Re: Cleaning the EGR Valve

Since thats two people now destroying their glow plugs by touching the control unit with a spanner whilst cleaning the EGR.

Disconnect the battery before starting!!!
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Old 02-08-2010   #10
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Re: Cleaning the EGR Valve

Thanks Aircooledbug for a great guide. It really helped me. It looks a daunting job but take your time and it comes apart as you set out. My EGR was well sooted up and the valve hard to move - with the unit split apart and a good brush out with carb cleaner it really cleaned it up and freed the valve. I just worked with wd40 on the solenoid end. It was a real fiddle to refit back on the engine but as you say patience pays. And the car is now running much smoother on tickover and sharper on acceleration. Thanks again for posting the guide. Cheers.
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Old 02-01-2011   #11
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Talking Re: Cleaning the EGR Valve

Wicked, nice pics by the way and helpful guide too : )
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Old 05-01-2011   #12
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Re: Cleaning the EGR Valve

I used this thread to fix mine,also the solenoid was jammed so i followed another web site on how to free the electrical part.

had it in the garage to turn the MIL light off
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Old 02-04-2011   #13
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Re: Cleaning the EGR Valve

Thanks a million for this guide - I've tried to thank all the other posts on this site that have helped by correctly giving part numbers, confirmation that an equivalent Vauxhall EGR valve will work, and where to find that part on eBay cheaply.

Symptoms I was having:
-Loss of power, to start off with at 1500-2000rpm
-after a week, power loss across most of rev range
-running very unevenly under hard acceleration
-low engine braking on overrun
-engine continues to splutter for a second after ignition key switched off

Took EGR valve off according to this guide - info about not losing seal from bottom of pipe was invaluable - I was ready to catch it.

Interestingly, my EGR was not particularly crudded up, although I'm only on 33,000 miles. But the new EGR completely fixed the problem. So I'm thinking as per some other threads on here the issue is not caking up with soot as much as the EGR solenoid failing.

I'm now driving with a big smile again!
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Old 02-07-2011   #14
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Re: Cleaning the EGR Valve

My Doblo 1.9JTD was showing all the classic symptoms. Followed the excellent guide above and here are my thoughts.
Dis-connecting the battery is a MUST.
Removing the fuel filter assembly takes minutes, 2 nuts, 3 q/d pipes and 3 elect. plugs, and gives loads of workspace.
Access to the bottom clamp on the lower pipe was impossible on mine without major dis-assembly so I just took the EGR off at the top joint - checked the pipe and it was a bit sooty but not too bad so left it alone.
What looks like a gasket between the solenoid and the EGR is actually a spacer. It actually vents to atmosphere, my theory is that the vents are to release pressure from exhaust gas seeping along the valve stem and that may be part of the problem. The vents on mine were blocked with carbon so crud builds up behind the valve, eventually causing it to jam. Anyway, I've cut a couple more vents in that spacer, have to wait and see if it helps - about another 52k miles ;-)
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