Hello

Today driving on the motorway i was doing 60mph and then when i put my foot down i had no power. I had my foot flat to the floor and i was only managing about 30mph, so i pulled onto hard shoulder and switched off engine. I started it again and tried to pull away but stalled very easily. Anyway after a few miles of struggling to get past 40mph i pulled over. I called the RAC out and he reckons its the egr valve. On two diagnostic machines it has flagged up a problem with the valve. Does this sound like the egr valve has finally packed up? A local auto electrician also reckons it is. However he won't just replace the valve. He wants to put it on a diagnostics, check engine over and then probably replace the valve. Is all that worth doing if people suspect its the valve? Thanks. Phil

If the engine is an 8v JTD there's an easy way to confirm its the EGR, by blanking it off with this.
http://www.ebay.co.uk/itm/EGR-blank...UZUKI-1-9-ALFA-1-9-2-4-CADALLAC-/120857185986

Once the EGR is blanked off take it for a drive, if power has returned the EGR is faulty, may just need cleaning, worth a try before you part with your hard earned cash.

Here's a guide to tell you how to clean it.
https://www.fiatforum.com/stilo-guides/263681-clean-egr-valve-1-9jtd-8v-engine.html

And here's a quick vid I made when I cleaned mine.
[ame="http://s296.photobucket.com/albums/mm189/Shadeyman67/?action=view&current=04072011075.mp4"]04072011075.mp4 video by Shadeyman67 - Photobucket@@AMEPARAM@@http://vid296.photobucket.com/player.swf?file=http://vid296.photobucket.com/albums/mm189/Shadeyman67/04072011075.mp4@@AMEPARAM@@vid296@@AMEPARAM@@296@@AMEPARAM@@mm189/Shadeyman67/04072011075@@AMEPARAM@@mp4[/ame]

Shadeyman said:

If the engine is an 8v JTD there's an easy way to confirm its the EGR, by blanking it off with this.
http://www.ebay.co.uk/itm/EGR-blank...UZUKI-1-9-ALFA-1-9-2-4-CADALLAC-/120857185986

Once the EGR is blanked off take it for a drive, if power has returned the EGR is faulty, may just need cleaning, worth a try before you part with your hard earned cash.

Here's a guide to tell you how to clean it.
https://www.fiatforum.com/stilo-guides/263681-clean-egr-valve-1-9jtd-8v-engine.html

And here's a quick vid I made when I cleaned mine.
04072011075.mp4 video by Shadeyman67 - Photobucket

Click to expand...

It has been blanked off before because i had power loss issue, it would lose power for a second then come back. However i had the plate removed at the last service and its been ok till today. Also is lots of black smoke normal when the car is reved at stand still? Phil

From what you've said I'm 100% sure its a faulty EGR.

The EGR gets blocked up with crap from the exhaust over time, many people(myself included) permanently blank them off once they have cleaned the EGR to prevent them blocking up again.

My advice is clean the EGR then permanently blank it off.

My mechanic friend is checking it out on Saturday. He also suspects egr valve. Hes going to block it off again and test it! Thanks for your help. Phil

Shadeyman said:

From what you've said I'm 100% sure its a faulty EGR.

The EGR gets blocked up with crap from the exhaust over time, many people(myself included) permanently blank them off once they have cleaned the EGR to prevent them blocking up again.

My advice is clean the EGR then permanently blank it off.

Click to expand...

Although you seem pretty sure its the EGR valve is there however any chance it could be a turbo problem? I'm just hoping the turbo hasn't failed

I've also had flat spots (around 2.5/3k revs) for a while now and I'm sure I still had them even with the EGR valve blanked off. So in the case of the flat spot issue, could that be something else causing them?

Thanks again

Phil

philipb82 said:

Although you seem pretty sure its the EGR valve is there however any chance it could be a turbo problem? I'm just hoping the turbo hasn't failed

I've also had flat spots (around 2.5/3k revs) for a while now and I'm sure I still had them even with the EGR valve blanked off. So in the case of the flat spot issue, could that be something else causing them?

Thanks again

Phil

Click to expand...

The crap from the exhaust that causes the EGR to stick and cause problems, also creates problems when it enters the inlet manifold via the stuck EGR. The MAP sensor measures boost pressure in the inlet manifold, this sensor gets covered(sometimes blocked) by the crap from the exhaust resulting in incorrect signals being sent to the ECU so incorrect boost can be the result.

I doubt very much the turbo has failed as they are quite robust. Its more likely something controlling the turbo is at fault. You already know you have an EGR problem so the MAP sensor is the most likely suspect. Take it out and give it a clean with electrical cleaner.

Here's how I do it.
[ame="http://s296.photobucket.com/albums/mm189/Shadeyman67/?action=view&current=WP_000033-1.mp4"]WP_000033-1.mp4 video by Shadeyman67 - Photobucket@@AMEPARAM@@http://vid296.photobucket.com/player.swf?file=http://vid296.photobucket.com/albums/mm189/Shadeyman67/WP_000033-1.mp4@@AMEPARAM@@vid296@@AMEPARAM@@296@@AMEPARAM@@mm189/Shadeyman67/WP_000033-1@@AMEPARAM@@mp4[/ame]

Thanks for the video, I didn't realise the MAP sensor was as small as that! The plastic engine cover is alread off because the RAC bloke needed access to the EGR valve so I'll give it a clean. But can you tell me exactly what bit do I clean - connectors or the do I spray the whole sensor?

Phil

The sensor has a short tube with an O ring on it. This protrudes into the manifold, you'll need to clean inside it. Do not poke things inside, you may damage the sensor, just use the power of the spray(electrical cleaner) to remove the crap(protect your eyes). Take a look inside the hole in the manifold, make sure its clear(I used a small mirror to help me see inside).

Thank you Shadeyman you have been very helpful Its a good thing i've got nearly a full can of Halfords electrical cleaner in the shed

Before I forget, what size was the bit you used to unscrew that little bolt?

Phil

5mm(I think).

I dropped the car off earlier. After revving it my mechanic says it sounds like an exhaust restriction. Be interesting to see what it is then. Phil

Yay, problem solved! Its the EGR valve, its well and truly knackered.

So do you plan to replace it?

If you do I believe there's a Vauxhall EGR that is a direct replacement for the Fiat one, could save you some money.

Shadeyman said:

So do you plan to replace it?

If you do I believe there's a Vauxhall EGR that is a direct replacement for the Fiat one, could save you some money.

Click to expand...

Yeah i'm going to replace it. I'll have a look into the vauxhall egr valve. Thanks. Phil

Does it matter what make of egr valve I get or is an egr valve...just an egr valve? My local motorspares shop has quoted me £134 inc VAT. don't know what make that is though.

Phil

I believe the Vauxhall EGR can be brought on eBay for about £80 so there's a substantial saving to be made.

I removed the MAP sensor and it looked ok but gave it a blast with electrical cleaner anyway. Afterwards i drove the car and didn't really notice any difference. The flat spot is still there but it tends to happen around 3k revs - MAF problem? Also i had to improvise with tools to remove the MAP and dropped a toolbit and can't find it, i'm sure it didn't drop onto the drive. Will it damage anything? Phil

Can anyone help? I've looked with an LED torch and still can't find it, is there anything at the bottom of the engine that it could have falled onto? I've looked around the glow plugs but I can't see it resting there.

Phil

philipb82 said:

I removed the MAP sensor and it looked ok but gave it a blast with electrical cleaner anyway. Afterwards i drove the car and didn't really notice any difference. The flat spot is still there but it tends to happen around 3k revs - MAF problem? Also i had to improvise with tools to remove the MAP and dropped a toolbit and can't find it, i'm sure it didn't drop onto the drive. Will it damage anything? Phil

Click to expand...

You probably wont find it.

The vibrations from the engine when you drove it most likely dislodged it and its now lying in the gutter somewhere.