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Old 15-08-2017   #1
Join Date: Dec 2014
Location: Grantham
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United Kingdom 
GP 1.6 diesel 955a3000 EGR clean

Tools required

10mm spanner and socket
T30 Torx
M5 Allen Key
Phillips screw driver
Small flat head screw dirver
small nylon brush, rags

Carb cleaner or similar
Observe all the common sense safety precautions and also if you feel the need disconnect the battery as there is work on close proximity to the glow plug relays. Personally I think there is plenty of room but thatís because I have done this job a few times, it takes about 1.5 hours depending on the challenges you are presented with. I am not mechanic so this s how I did it and Iím sure there are areas that are incorrectly termed. I used ľ drive kit as this is all small items torque settings by hand as the 1.6 is woefully documented.

Chances are you have experienced the odd hesitation or even had the check engine light illuminate and on checking the fault code it indicates an EGR related issue, this guide is intended to allow you to remove and clean the EGR Valve on the 955a3000 engine 1.6 Mjet.

Park on a level surface, allow the engine to cool sufficiently. Open the bonnet and remove the engine cover, this is a case of pulling it up off the four rubber mounting points.

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Remove the vacuum pipe by pressing the red detents and pulling away, then open the retaining pipe clip with a small flat bladed screw driver, tuck the pipe out of the way.
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Remove the x2 10mm M6x18 bolts holding the throttle body intake on, push this out of the way towards the battery and tie back as this will enable you to deal with the throttle body without it getting in the way.
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Remove the throttle body, x3 bolts of which the upper 2 are 10mm M6x18mm and the lower is 10mm M6x50mm, this also has a cable retainer attached. Rotate the throttle body and disconnect the black connector by pulling out the yellow tag and then removing the electrical connector.
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Next using a mirror to view the rear of the engine on the right hand side as you look from the front familiarise yourself with the EGR valve, the link pipe and associated fixings and finally the EGR electrical connector.

Remove the electrical connector, light brown following the same method as for the one on the throttle body. Yellow clip, the release the main connector. Tuck the wire out of the way.

Remove the EGR valve x2 Pan Head T30 Torx M6x38mm, the EGR valve will then slide out about 1.5 inches towards the bulkhead and then it is free to be removed from the car.
Attachment 1
The EGR pipe to the left of the EGR valve is removed by undoing the upper joint which is 3 10mm bolts M6x12mm and the lower joint which is 2 Cap M5x23mm. the pipe will then remove with a twist required as there is a bent section that curves into the inlet manifold.
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The EGR valve can then be separated on the workbench by undoing the x4 M4x16mm machine screws, this allows you to keep the electrical section of the valve well away from the cleaning of the valve.
The valve can be cleaned with EGR cleaner, rags nylon brushes etc and I also used.
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Post cleaning the car felt like new, so smooth and no hesitation.
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Old 15-08-2017   #2
Join Date: Dec 2014
Location: Grantham
Posts: 260
Thanks: 13
Trader Rating: 0
United Kingdom 
Re: GP 1.6 diesel 955a3000 EGR clean

Not sure what the bear is doing in there this is the 2 Torx holding the valve onClick image for larger version

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