Lets talk 1.9 MJet EGR? Or should the 3 letter acronym be DSS... Diesel Soot Storage!?

Right there is plenty about this on the Forum but really....

Do we have ALL the symptoms in a single place to make it easy as pie for owners to get all the info they need to judge wether or not to remove / clean & re-fit? As opposed to a dodgy MAF or TPS for example?
To give the best chance of getting it right...

I've attached a couple of pics of mine below, there are others, but just so they are "here"!

Now what owners of the 1.9 JTD derived MJet want to know is how do they know for sure what the EGR clog=up signs are?... what different symptoms did we have?

Mine...
NO power up to 2,200 RPM then whooosha!
Black smoke over 3,000RPM.
Drop in economy by 5 - 6 MPG.
A brief showing of the EML & "Check Engine" message.
Heavy judder from the engine when seitched off.
Add your own symptoms.
Attached are my 2 pics... suffice it to say it was totally clogged up, easy to clean as per Aircooled doodlebug's guide, removing & re-fitting would always be a pain in the a$$ with my big hands & short fingers so I had a new EGR fitted, I now have a cleaned up example ready for use!

Be aware that there's 2 side venturi to clean out as well... easily missed at the opposite end from my 1st pic, I cleaned these out with a plastic cable tie... repeatedly until no soot came out by flushing & brushing!

Great idea Ffoxy

Mine started with a momentary flat spot around 2000rpm that only I could notice as the driver (passangers were blissfully unaware). This went on for about a month or so then one day the flat spot increase on the way to work spanning from around 1800rpm to 2100rpm but appeared normal above and below these revs so I got it booked into Fiat to be checked out.

The following day I got out of my road and then it felt very unresponsive at any revs below 2500rpm and then it would surge with power. I got about a mile down the road and stopped at the lights, went to pull away and it was pretty much undrivable.

I managed to limp it to the office and park up - Driving it through the gears managed a grand total of about 25mph in 6th gear.

Once I switched the engine off that was it, I couldn't get it started again. It got recovered to the dealers where they diagnosed the EGR failure.

Recon EGR valve fitted under warranty and all was good again.

Hope that helps

How often/miles do these got clogged?

OLZ said:

How often/miles do these got clogged?

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It varies, no-one is sure why, may be driving style / conditions, may be fuel quality, could be some of all the above.

Mine went 62,000 miles, I have seen some Posts where they failed at 20,000 or less.

IMO these should be a Major service item, an hour & a half should see it done, but would owners want to pay for cleaning, or wait until it fails...?

Si - Punto said:

Great idea Ffoxy

Mine started with a momentary flat spot around 2000rpm that only I could notice as the driver (passangers were blissfully unaware). This went on for about a month or so then one day the flat spot increase on the way to work spanning from around 1800rpm to 2100rpm but appeared normal above and below these revs so I got it booked into Fiat to be checked out.

The following day I got out of my road and then it felt very unresponsive at any revs below 2500rpm and then it would surge with power. I got about a mile down the road and stopped at the lights, went to pull away and it was pretty much undrivable.

I managed to limp it to the office and park up - Driving it through the gears managed a grand total of about 25mph in 6th gear.

Once I switched the engine off that was it, I couldn't get it started again. It got recovered to the dealers where they diagnosed the EGR failure.

Recon EGR valve fitted under warranty and all was good again.

Hope that helps

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Cheers Si... I'll put all offerings together at some point for a quick ready reference on EGR faults for the 1.9 MJet... maybe a Mod will suggest it as a Sticky...?

If it only takes an hour and a half il be cleaning mine every 10,000 for sake of more mpg and power

Just quickly while i've got a few people that know what there on about in this thread, I want to fit a dump valve to my M-JET (I know there will be no power gains) similar to this one:


Is that noise stalling of the turbo and does it have a negative affect on the turbo?

ps. what a gayboy with playboy stickers on his car. ^^

Hmmm a DIY clean up is do-able... quite a few have done it, removal & re-fitting is awkward though unlesss you have 6inch long fingers & miniature hands...

Not sure about the DV TBH, not something I'd want to do, I prefer a silent sleeper!

Try a Search, I'm pretty sure its been asked before, but the MJet has a variable vane Garrett turbo so as you say nothing to gain... not a fan of Tishhhhhh... bit chavvy at my age lol!

Just to clarify, i'm not a chav..at all
I just love the sound, not after the "tsshhhh" anyway I wan't that turbo flutter/stall sound.

And with regards to making this thread a sticky it gets my vote as it looks mega helpful!

OLZ said:

Just to clarify, i'm not a chav..at all
I just love the sound, not after the "tsshhhh" anyway I wan't that turbo flutter/stall sound.

And with regards to making this thread a sticky it gets my vote as it looks mega helpful!

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Lol nah... I did say for me at my age

I'm not sure you'll get the turbo flutter because of the variable vane turbo but I know nothing of it OLZ soz.

My sleeper takes all sorts completely by surprize... Shock & Awe...

Haa, you have no idea how excited I am to get mine! Il get it feb hopefully

Get a GSR if you want to hear the turbo more. DV's are crap on dervs and the novelty of one would soon wear off.

GSR is best for this tbh, Il be at most of the Auto Italia shows this year so if you want to hear it

Took me 45 minutes and made easier as I have quite small hands, (needed to get the vertical pipe away from the exhaust lower down)

Once the weather starts to be come nice again then I'm tempted to strip it down and see how its going with the modified gasket.

PS We should collect the usefull part no's too in here.

Heres the gaskets

71751469 - Modified/Swirl Gasket - 1 Required Approx £12 - Shown Centre

46773082 - Standard Gasket - 4 Required approx £1.80 - Shown Left & Right

alexh365 said:

Took me 45 minutes and made easier as I have quite small hands, (needed to get the vertical pipe away from the exhaust lower down)

Once the weather starts to be come nice again then I'm tempted to strip it down and see how its going with the modified gasket.

PS We should collect the usefull part no's too in here.

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Indeedy! That will be interesting & if successful very useful to other owners.

Lol at small hands... I've got shovels and sausages! Tried but NFC!

i dont mean to be dumb but i have cleaned my egr valve and it was filthy at only 22,500 miles, i am still having problems and the car is undriverble . does this mean my egr valve needs replacing? and what part electrical/mechanical? i am unsure as all the parts moved freely. oh and final quetion what is the damage to my wallet going to be?

ricec87 said:

i dont mean to be dumb but i have cleaned my egr valve and it was filthy at only 22,500 miles, i am still having problems and the car is undriverble . does this mean my egr valve needs replacing? and what part electrical/mechanical? i am unsure as all the parts moved freely. oh and final quetion what is the damage to my wallet going to be?

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Did you also find & clean out the 2 side venturi when you cleaned out the soot? Mine were both blocked... invisible... I got the idea of a video of a guy cleaning out an EGR on his Toyota...

My EGR cost me £145 fitted at my fave independent Service Agent (non-Fiat), genuine part, inc gaskets & swirl gasket mod.

I also had an Interim Service, total £315 inc all labour, materials & VAT.

Trade up for Tjets you wont have this problem.

punto_matt said:

Trade down for Tjets you wont have this problem.

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No Matt... just no.... even with the EGR issue the MJet is totally wikid innit!

itz mint at dis tyme ov da yr az u cn plow da feelds enit.