Hi there,
Am a new owner of a JTD 115 which ain't brilliant at mpg & seems a bit down on power. Reading other input it would seem a good idea to clean out the EGR valve (rear of engine on rhs). Question is... how do I remove it? Some detailed info would be really welcome.
Thanks in advance,
Mike

mikecarty51 said:

Hi there,
Am a new owner of a JTD 115 which ain't brilliant at mpg & seems a bit down on power. Reading other input it would seem a good idea to clean out the EGR valve (rear of engine on rhs). Question is... how do I remove it? Some detailed info would be really welcome.
Thanks in advance,
Mike

Click to expand...

Hi Mike,

Click on this link and all will be revealed > https://www.fiatforum.com/multipla/153584-egr-location.html

You might also consider thinking about the mass airflow meter that can effect the performance of the JTD

I got as far as trying to gain access to the 2 allen bolts connnecting the EGR to the bottom pipe. In the link it says push the EGR back to the bulkhead as far as poss. Will the not so flexible pipe take the strain?
Regards,
Mike

Mike

Somewhere else in this forum was a very helpful post that suggested another (easier?) way of doing it, which worked for me. I'll find it in a tick. Basically unscrew only the four small allen screws securing the electric solenoid (the part at teh left hand end) and then cleaning the valve by spraying with carb cleaner. This only took half an hour, was easy to do and my 1.9 now has much more power, and no smoke.

Pete

Here's the previous post (Neil - thanks -- worked beuatifully)
https://www.fiatforum.com/multipla/139462-egr-valve-electrical-type.html
(Just be careful not to loose the bottom allen screw!)

Hi Pete,
Thanks for the tip. I'll give it a try. I assume that when the valve is separated there will be nothing that either falls out or springs open!
I wonder how they do it at the main dealers?
Mike

Mike.
No, nothing springs out. But, there are four allen bolts to remove. Do the bottom ones first, the bottom back one needs care so you don't drop it down into the back of the engine bay (magnetic allen driver helpful) . Doing the top one last helps here.

The solenoid pulled away from the valve leaving a gasket ring and a solid build up of soot (mine's done 80,000 miles). Poking that soot gently with a small screwdriver made a lump of it fall out, revealing the valve 'plunger'. I didn't try removing this - only cleaning it with the spray and pushing it in and out as I did this (with paper towels under the housing to catch the very black run-off). Similarly, cleaned the internal end of the solenoid housing which was equally black and coked up. Reassembled and all was well. Drove away, deliberately revving higher than normal through the gears. Initially quite a bit of smoke, but soon cleared, and power and acceleration now 'as new' again. Total cost: 1 hour of my time and one can of carburetor cleaner (Note: don't get this on the paintwork - smells strongly of cellulose thinners!)

Dealers in general no longer seem to dismantle anything - just replace whole units...
Pete

Hi pete,
Thanks for that info. Finally managed to separate the valve & removed the build up of carbon. Will check on performance & mpg in the coming days.
Regards,
Mike
PS have posted another thread re a problem of accelerator pedal jerkiness at small throttle openings. Any ideas??

Mine is a 1.9 JTD 2007 80,000 miles, had exactly the same problem, down on power loads of black smoke coming out the exhaust when i booted it, so tried cleaning the egr valve.

Could I get the last of the 4 screws undone, could I bugger (the one at the back that connects the black bit to the metal bit, sorry not sure what the correct term is). Anyway, long and short of it is, managed to get the 2 bolts undone that connect the corrugated metal tube to the right bit of the valve.

Sprayed in carb cleaner and cleaned in situ, seems to have done the trick.

But, I think I have worn the head off the 4th screw, I couldn't undue, would like to get the bugger off so I can try to clean from the other side, any ideas?

Just an update, couldn't get the 4th screw off so decided to disconnect the two bolts on the underside of the egr that connect the metal pipe to the bottom. Could I unscrew them, nope, (why do bolts have to be done up so tight) took it to a mechanic I know, he couldn't unscrew either, in the end had to heat the thing up with a blow torch, to losen.

Anyway took the whole unit out of the car, took apart, the whole of the back of the unit was completly full of soot. Cleaned it all out put back together, and the car runs sweet. If you are able to do yourself would highly recommend you give it a go. Car has plenty of go now, and the mpg seems a hell of a lot higher than was previously.