156 Sportwagon 2.4 JTD ( 140bhp engine with black and silver cover )
Teach me not to fiddle.
Right this is what I did.
I set out to clean the EGR valve, and to look at clean the airfilter.
Did the airfilter first, took off the pipework and MAF, but due to rusty nuts didn't get to the filter. insepcted MAF ( I did not clean it ), re-assembled. All straight forwards.
Then took engine cover off to access EGR unit - took all bolts of OK, except the one one the bottom ( connecting the pipe - see No 1 in pic ) wouldn't budge - so went no further.
I did not re connect pipe No 5 - as I saw that the unit it fit onto ( The one with the butterfly valve ) had some gunk in it , which I cleaned out as best I could. I took off the intercooler pipe, and its metal pipe exposing the butterfly valve, and cleaned up any oil etc.
Re-assembled with no problems. While the engine cover was off I sprayed the head where the glow plug are lightly with WD40, then put the cover back on.
I THEN WENT FOR A SHORT TEST DRIVE, AND THIS IS WHAT HAPPENED:
Started no problem at all. Pulled off and drove fastish up the road. All fine. Turned around to go back, pulled off quite fast in first, fine. Changed to second, and it completely slowed down with it being very hard to rev. It was very smooth, but the revs would build incredibly slowly, and not get over 2.5k revs.
Go home, and parked up. Tried again to rev the engine, but still wouldn't rev.
WHAT HAVE I DONE!!!