Update on the dreaded EGR...
The valve came out no problems. 10mm socket and spanner and I think a 13mm socket.
Had to move the rubber pipe out of the way first, was fouling the spanner.
I noticed the build up of "soot" immediately. Absolutely caked in the stuff. It was so think that I could actually see the issue with the no power then loads of power. The flow of gas was blocked until the valve was fully open, hence the low down sluggishness followed by a whoosh of power!
Took the solenoid off, again, the union between them was caked in soot.
Sprayed carb cleaner in and out of the valve. Used a screwdriver to remove chunks of the stuff. Then left it in a bucket of very hot soapy water.
I drilled the hole in the top of the solenoid, but the interior parts were solid, it wasn't budging and I was beginning to get scared that I would bent/dent the insides if I tried any further. So gave up on this one.
Instead I sprayed the carb cleaner inside via the hole I had made, and at the part where the solenoid pushes the pin out. Quite a bit of gunk came out at this point.
Once the valve was thoroughly soaked I cleaned the rest of it with a rag and screwdriver. It looked like new!
I sprayed the solenoid and the valve with lashings of liquid grease, then pieced back together, making sure the two lined up correctly.
Replaced back on the car (after cleaning the gaskets carefully) and bolted back together. The lower flange and gasket was a bit fiddly, but all back nice.
Big test, key in, pressed the button.........started and no warning lights! Phew.
A quick raz up the road, and the car is transformed. Unbelievable difference. Pulls from 1K revs and keeps going, no weak spots, no sudden gush of power. I can actually feel the remap now!
Then...............as I was returning home, with a grin on my face, I heard a "click, click, click" in time with the rotation of the wheels. Hoping it was a stone in my all but brand new 18" tyre I went home for a look. The largest screw head I have ever seen! Right on the boundary of the tread and wall. Grrrr...
Off came the wheel, over to the local tyre place, a bit of sucking of teeth and asking questions of the boss, then they agreed to repair it. Phew.
Wheel back on, all nice. Except that the headlight bulb had gone now!!! For the sweet love of the baby jebus and the orphans!!! What next. So £5.99 later, new bulb.
A shame that the last two events kind of took the sheen of a successful mornings work really. Oh well, these things are sent to try us eh?!
Will give the car a good run tomorrow, check how it feels under load and at temp. Fingers crossed!
to Kev for the instructions and advice, you are a star mate. Thanks.