My GT lit up the EGR warning when it was still under warranty. No noticeable performance difference until after the new one was fitted.....
I suffered for 10 months with slight hesitation at low revs (new MAF also fitted under warranty didn't help) until it finally really started playing up. The car would lose all power for about 20 seconds and then burst into life. When I dropped it off for diagnostics at the garage it wouldn't drive over the drain at the garage door!! When connected up to the diagnostic tester, it was fine and drove great... At no time did the ECU provide a fault light or code.
Cleening the EGR (which I can now do in about 15 minutes) was a lottery, sometimes it worked great after a clean, other times it was even worse.
Finally, just after the 12 month warranty expired on the replacement EGR valve, I bought a replacement. Problem cured instantly. Car has driven perfectly for the past 18 months.
Moral of the story, never assume that a new part in an Alfa parts box is going to work as it should!
On further inspection, it was clear that the valve spring had much less tension than it should. Obvious to see when compared to the replacement one.
"When you sit in a Focus RS or a Golf R32 itís like sitting in a commercial for Lynx aftershave. When you sit in an 147 GTA itís like sitting in a Venetianís hand-made suitcase." J.Clarkson 2003.
Current fleet: 156 Sportwagon jtd 16V (facelift) 2.4 Spider, Leon Cupra SC
Projects: Spider S4, Matra Murena 2.2