Having just endured the joy of removing/replacing the EGR and
exhaust gas heat exchanger after 110000 miles on my 1.3 MJT
after it started pulling 0401 fault codes I found that the problem
was confined to the inlet manifold exhaust gas injector holes blocked. The corrugated stainless tube from the heat exchanger to the inlet manifold is welded at the heat exchanger end but
I was wondering if there is enough flexibility in the corrugated

tube to get injector tube out of the inlet manifold without removing the EGR? The tube seems quite stiff.

Is it possible to hear the EGR operating with an engine stethoscope?

How does the ECU detect low EGR gas flow? There are no obvious sensors in the EGR system.

The exhaust gas injector was covered in stick black gunk but
the interior of the inlet manifold seemed quite clean, I assume the source of the muck was the crank case ventilation.

mhs06 said:

Having just endured the joy of removing/replacing the EGR and
exhaust gas heat exchanger after 110000 miles on my 1.3 MJT
after it started pulling 0401 fault codes I found that the problem
was confined to the inlet manifold exhaust gas injector holes blocked. The corrugated stainless tube from the heat exchanger to the inlet manifold is welded at the heat exchanger end but
I was wondering if there is enough flexibility in the corrugated

tube to get injector tube out of the inlet manifold without removing the EGR? The tube seems quite stiff.

Is it possible to hear the EGR operating with an engine stethoscope?

How does the ECU detect low EGR gas flow? There are no obvious sensors in the EGR system.

The exhaust gas injector was covered in stick black gunk but
the interior of the inlet manifold seemed quite clean, I assume the source of the muck was the crank case ventilation.

Click to expand...

hi, im not sure whether anything im about to say will help but worth a shot right!
so ive also just had my egr replaced as it was showing the same code. however, luckily, mine then cleared afterwards. so ill just give you a list of things to try and clear some of the stuff out that could be causing you problems.
firstly, have you tried a spray egr cleaner? you spray them into the air intake and it then gets round to the egr and starts cleaning the gunk out. this could work if its just stuck onto where ever the sensor picks up. the ecu maybe thinking its alot worse than it actually is if it is blocking a sensor.
also check the MAP sensor, mine was FULL of carbon when i changed it. it was causing all sorts of air flow issues. so give it a check, mainly because its easy to do and wont do you any harm.
lastly, you can remove the actual solenoid from the egr. im not sure if that gives you more room, but just a suggestion. i cant remember how it all looks, i tried to block that nightmare out!
hope this help, and if not have a good day
cam

I looked at the listed content of the EGR valve cleaner spray and

could not work out how it would help the EGR as the gas flowing
through the EGR is exhaust and it looked as if all the spray
would be burned in the cylinder, so decided to go for the remove
and clean route. Having removed the EGR valve I found that the
valve was operational and the interior of the valve and heat
exchanger were just covered with a light carbon deposit and

that the blockage was all in the exhaust injector cone inside the
inlet manifold I now see that the cleaner might have helped as
the blockage is directly exposed to the inlet air stream.

Hopefully I shall not have to repeat the EGR cleaning process
but my main questions were:

Is it possible to detect if the EGR valve is operating without
dismantling by listening for the solenoid movement?

Is it possible to dismantle the exhaust inlet injector from the
inlet manifold by bending the corrugated pipe from the heat
exchanger to enable removal of the exhaust injector cone
without removing the EGR from the engine?

I have not yet investigate the possibility of cleaning this area
by removing the inlet manifold.

Having discovered the location of the problem I would be more
inclined to try the EGR valve cleaner but have heard that I can
cause problems with the air flow sensor.