Technical Yet another EGR thread!!

[Mark075]

I recently bought a Bravo 1.9 120 Dynamic. I started to get the check engine warning message when starting the car. There was no MIL light thereafter and the car drove perfectly.
I removed the EGR Valve and cleaned it thoroughly with Carb Cleaner. There was quite a lot of soot and the spring loaded valve was quite sticky. Once finished it was nice and clean and the mechanism moved freely as it should. I put it back on the car and then continued to use it expecting the engine warning to stop. It didn't however and if I clear the code (P0401) using my diag unit, the warning soon comes back.
I removed the EGR again and this time turned my attention to the solenoid. The piece that sticks out (the plunger?) appeared to be stook in situe (about 1.5mm out of the housing) so I grabbed it with some pliers and pulled it out as far is it would go. I then sprayed some wd40 on it and worked it back in and out. Once finished it moved freely and springed back into position as it should.
I then put it back on the car and now the car struggles to start, runs rough, has little power and I am getting the additional code - P0403 - Exhaust Gas Recirculation Circuit Malfunction.:bang:

I'm cheesed off as at least the car ran perfeclty before I tinkered!

Any ideas whats going on?

 

[LeighPing]

Any ideas whats going on?

Not really Mark but check these EGR clean up posts and see where you might have gone wrong. Then maybe it's time for number 5.

 

[Mark075]

Cheers for that. I wonder if when I messed with the solenoid it is causing the valve to stick slightly open (as apposed to closed as before).
I've orded a new saab 1.9 120 EGR (same part number) Valve from ebay and it's due to arrive today. Heres hoping it fixes the issue!

 

[Mark075]

Aggh, I replaced the EGR Valve and now car is flat between 1000 and 2000 rpm and then it flies. I don't understand why this would be. Any ideas?:bang:

 

[sismithin]

I had the same thing with mine, I cleaned the MAP and MAF and then remembered to keep using some millers Ecomax additive when I filled up and it sorted it out, car now runs like an absolute dream still.
Check out these posts, see if they are similar https://www.fiatforum.com/bravo/332712-lack-power-my-head.html

 

[LeighPing]

I had the same thing with mine, I cleaned the MAP and MAF and then remembered to keep using some millers Ecomax additive when I filled up and it sorted it out, car now runs like an absolute dream still.
Check out these posts, see if they are similar https://www.fiatforum.com/bravo/332712-lack-power-my-head.html

Based on your recommendation I bought some of this today and then filled up with v-power nitro diesel. £1.56 a litre. Ouch, hope it was worth it.

 

[sismithin]

Based on your recommendation I bought some of this today and then filled up with v-power nitro diesel. £1.56 a litre. Ouch, hope it was worth it.

£1.56 oooch I'm sure it will do a world of good, whack in a fair bit of Millers and I'm positive you'll feel the difference.

I'm still running asda fuel, but notice the difference when I don't use any additive.
First time around it took about 200 miles to really feel the difference, like it says on the tin haha

Cheers
Si

 

[Mark075]

I cleaned the MAP sensor - it was all sooted up etc. Once cleaned it still looked like it had seen better days. I've ordered a new one (un-branded ) and I will fit that to see if it helps.

I also took the MAF sensor off (only to realise it is a completely sealed unit) and tried to clean but unable to truely get in to do the job properly.

Interestingly, on Friday I took the car into my local indy garage to have timing belt and water pump changed and at the same time he cleared a load of old codes from the ECU (around ten apparantly). Since then it definatley drives a lot better but I am still getting 'check engine' and it isn't quite as responsive as before I started tinkering.

I can see me having to change the MAF sendsor next. This is getting rather costly!

 

[Mark075]

Just to give an update, I replaced the MAP sensor and this has not made any difference. The car is still driving ok (ish), but the engine is still registering faults. I was changing the oil last night (the sump plug was seized so had to syphon the oil out - thats another story though!) and while the oil was draining I opened the air box up and dropped the folter out. It came out with a load of dust and cr*p and certainly didn't look in a very good way. Is it possible that this may be contributing to the problem (poor air flow) and perhaps its also knackered the MAF sensor? I'm picking up a new filter tonight and will be fitting it straight away.