Register Login
iNETFX Domain Registration - COM/NET/ORG 6.50 a year!
Comment
 
Guide Tools
<!-- google_ad_section_start -->Clean EGR Valve on 1.9JTD 8v Engine<!-- google_ad_section_end -->
Clean EGR Valve on 1.9JTD 8v Engine
Published by Hitby
22-02-2011
Unrated

User Rated:
Difficulty Level: 2

Show Printable Version  Email this Page 
Clean EGR Valve on 1.9JTD 8v Engine

NOTE: This is the article I wrote for the same procedure on my Saab 9-3. The engine appears to be exactly the same on my Stilo so I've reproduced it here.

What you'll need
I didn't really take any notice of the sizes I used so I've linked to sets instead. I had a socket set and a torque wrench already, I just had to buy the Hex Key socket set.

Star bits to remove engine cover
Torque Wrench (low torque)
Hex socket set
Socket Set
Carb Cleaner

Location

The EGR valve is located at the back of the engine on the right looking at the car from the front.




Removal


Remove the engine cover by loosening the two star screws at the front and then lift off.

All in there are three bolts that need to be removed with a regular socket or spanner and four that you'll need a hex socket for.

DISCONNECT ELECTRIC PLUG Unclip the black plastic shround from around the plug marked in yellow then push in the clip and pull it off the EGR valve

REMOVE FOUR HEX BOLTS Firstly use your hex socket/wrench to remove the bolts marked in green, there are two attached to the engine block and two that attach a pipe on the underside of the EGR valve. I had to use an extension to undo one of these, it's quite tight but you can just about fit a standard wrench in to loosen them.

SAVE GASKETS There are gaskets in between the engine block and the EGR valve and the pipe and the EGR valve. I reused them so make sure you don't drop them.

REMOVE THREE BOLTS Remove the three bolts marked in blue. When you pull them out the bracket for the engine cover that is between the EGR valve and the engine (marked in white) will be loose and just pull out.

The EGR valve will now be off. Most likely it'll be completely coked

CLEAN EGR VALVE I used a toothbrush and carb cleaner. I sprayed loads in, do this outside where it's ok if you make a mess. It's filthy. WEAR GLOVES - I didn't and I still haven't got my hands clean! Make sure you've got it as clean as possible


CLEAN ENGINE INTAKE Where the valve attached to the engine block was filthy as well, I used a screwdriver to flick the carbon out and then a finger soaked in carb cleaner to rub around and get it a bit cleaner. Try not to let much of the carbon fall into the engine block

Reinstall EGR Valve
Reverse the removal instructions to reinstall the valve. It's fiddly but easy enough to do alone. Altogether it took me about an hour and a half to complete the job - I was taking my time so as not to drop anything etc. Note: When reinstalling; the three bolts that go through the engine cover mount into the engine block should be torqued to 25Nm.
Thanks GhostRider199, TD5, Fat H, Shadeyman thanked for this post
Likes Paddyjtd, raton_laveur liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

Old 24-02-2011   #1
Join Date: Sep 2008
Location: Wolverhampton
Posts: 6,093
Thanks: 286
Trader Rating: 7
Shadeyman has donated!
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

Nice guide.
Once you've cleaned the EGR, Manifold and MAP sensor permanently block the EGR off to stop the crap and problems that go with it happening again.

http://cgi.ebay.co.uk/EGR-blanking-plate-VW-SEAT-SKODA-KIA-FORD-AUDI-VOLVO-/120686493124?pt=UK_CarsParts_Vehicles_CarParts_SM= &hash%3Ditem1c1979bdc4
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

Shadeyman is offline Reply With Quote Quote 
Old 25-02-2011   #2
Join Date: Jun 2008
Location: Kent
Posts: 201
Thanks: 4
Trader Rating: 0
MiniMonster has donated!
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

Your Stilo is a 1.9 JTD 8Valve... do the petrol stilo's have EGR valves to clean? and potentially block off if intended? i.e. 1.6 16Valve Petrol
I am really interested in cleaning and maintaining every part of my cars engine, so this EGR valve and any other valve / component to clean in my 1.6 petrol I would be really really interested in knowing about!
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

MiniMonster is offline Reply With Quote Quote 
Old 01-03-2011   #3
Ex-Schumey proud owner
 
BLKC99's Avatar
Join Date: Jun 2010
Location: Top Gear Studios
Posts: 814
Thanks: 31
Trader Rating: 1
BLKC99 has donated!
United Kingdom 
Talking Re: Clean EGR Valve on 1.9JTD 8v Engine

Well appreciated guide, top man
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

BLKC99 is offline Reply With Quote Quote 
Old 26-05-2011   #4
Join Date: Jan 2011
Posts: 12
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

Quote Originally Posted by Shadeyman View Post
Nice guide.
Once you've cleaned the EGR, Manifold and MAP sensor permanently block the EGR off to stop the crap and problems that go with it happening again.

http://cgi.ebay.co.uk/EGR-blanking-plate-VW-SEAT-SKODA-KIA-FORD-AUDI-VOLVO-/120686493124?pt=UK_CarsParts_Vehicles_CarParts_SM= &hash%3Ditem1c1979bdc4
looks nearly like the cleaning of egr valve on a vauxhall site but not as thorough as both halfs need seperating to get at and clean the plunger, the bit that jams the valve.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

rick45 is offline Reply With Quote Quote 
Old 24-08-2011   #5
Join Date: Jan 2009
Posts: 4
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

What are the symtoms of a choked EGR valve?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

Fiddler is offline Reply With Quote Quote 
Old 26-08-2011   #6
Join Date: Jan 2009
Posts: 4
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

I decided to clean EGR Valve what a lot of gunk and it was very sticky. Thanks for taking the time to post the How to do it guide
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

Fiddler is offline Reply With Quote Quote 
Old 18-12-2011   #7
Join Date: Aug 2010
Location: mid wales
Posts: 136
Thanks: 2
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

Very useful guide thanks a lot.

If I may add to this, disconnect the connector at the bottom of the fuel filter, and after unclipping the pipes and undoing the two 13mm nuts the filter will swing out of the way making quite a bit more room to work.
Alsso remeber the flange on the bottom of the egr will rotate once its loose and the "easy" (relative term) allen bolt is removed, this makes undoing much easier.

My egr wasn't so much clogged, although it certainly needed a clean, but the valve itself was stuck open. I freed it up by spraying with wd40 and a lot of twisting and jiggling until it moved freely.
__________________
cledan is offline Reply With Quote Quote 
Old 10-01-2012   #8
Join Date: Jun 2011
Posts: 64
Thanks: 6
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

I thought if you block it off completely you get an engine fault light come on?

From other postings I was under the impression the part to use to block off the EGR valve has a small hole in the middle which somehow stops the error code?

I keep meaning to order one of these from ebay which I have saved in my watching list.

http://www.ebay.co.uk/itm/110796205572?ssPageName=STRK:MESINDXX:IT&_trksid=p 3984.m1436.l2649
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs


Last edited by wad2502; 10-01-2012 at 01:07.
wad2502 is offline Reply With Quote Quote 
Old 21-01-2012   #9
Join Date: Aug 2010
Location: mid wales
Posts: 136
Thanks: 2
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

ine has no hole in it, or them I should say, I blocked off both sides of the egr, so it can still actuate the valve to its hearts content, and thats what the ecu must think its doing as I've got no light on mine.
I thought you got the light on if you removed the egr?
__________________
cledan is offline Reply With Quote Quote 
Old 23-01-2012   #10
Join Date: Apr 2011
Posts: 15
Thanks: 0
Trader Rating: 0
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

I think congratulations are in order as I've managed tintake it off on my own in 2hours lol.

Just wondering if I can drive the car while the egr is in my house? ie not connected..

And how many people have blocked it off and not had any problems like engine light n stuff?

Btw my car was smoking black at high revs and loss of power at low revs but the egr isn't 'seriously' blocked, just abit dirty

Look forward to replys
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

slauta100 is offline Reply With Quote Quote 
Old 15-02-2012   #11
Join Date: May 2008
Location: South Wales
Posts: 292
Thanks: 16
Trader Rating: 0
Stuart_89 has donated!
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

will blanking off the egr fail your MOT on emissions?
__________________
05 Stilo 1.9 JTD 115 3 Door
Stuart_89 is offline Reply With Quote Quote 
Old 17-11-2012   #12
Join Date: Jan 2012
Location: Portsmouth
Posts: 12
Thanks: 0
Trader Rating: 0
Bertye has donated!
United Kingdom 
Re: Clean EGR Valve on 1.9JTD 8v Engine

Quote Originally Posted by Stuart_89 View Post
will blanking off the egr fail your MOT on emissions?
Hi, no. In Briton Diesel cars are tested for smoke output only (Opacity test), so will only help it pass the MOT as there will be less smoke. If the valve is faulty, then it would most probably fail, because there may not be enough Oxigen to burn the fuil fully, hance black smoke
http://www.ebay.co.uk/itm/1209287295...84.m1559.l2649
http://www.ebay.co.uk/itm/1109023139...84.m1559.l2649
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides | FAQs

Bertye is offline Reply With Quote Quote 
Comment
Currently Active Users Viewing This Guide: 1 (0 members and 1 guests)
 
Guide Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Guide Guide Starter Category Comments Last Post
(T) EGR valve - remove, clean & modify. shiningliao Stilo 87 07-01-2012 12:57
(G) To Clean Or Not To Clean?? EGR Valve JimbbobW1977 Grande Punto 6 13-03-2009 17:26
(T) what does your egr valve look like and how easy is it to clean? yellowperil Stilo 8 24-03-2008 13:53