Can an EGR stuck open cause a swirl flap failure
I'm new to the forum, but unfortunately very versed in the bad side of the experience that comes with owning an Alfa. A little bit of background, I own a 159 1.9JTDM 16V, late 2007 which I purchased about 15 months ago.
One month after I purchased the car, I encountered a check engine light, which turned out to be a fault with the EGR valve, which was stuck open. This was replaced under warranty from the garage I bought it off. About 8 months later, I had the car back in a garage where another engine warning light was diagnosed as a fault with the EGR valve, again being stuck open. I opted to have the EGR valve cleaned, as replacement was not an option for me at the time, and I could not make it back to the garage I had bought the car from as I had recently moved city. The car was out of sellers warranty at this point, but the EGR valve should still have been covered.
Another 4 months passed, and while driving in heavy city traffic, several swirl flaps were ingested by the engine, which was subsequently destroyed along with damage done to the turbo. The engine and manifold were replaced, and the turbo was re-conditioned (all by an Alfa main dealer) and when they ran their final tests, they noticed the EGR valve was again sticking. So it was replaced.
Not 2 months later, that replaced EGR valve was again deemed to be failing by the main Alfa dealer, and replaced under warranty. To sum up, this is my 4th EGR valve in 15 months.
I have 2 questions, which the main dealer has not been able to explain to me satsifactorily.
1. Why does the EGR keep failing? Once is unlucky and part of owning a JTDM it seems, but 3 times?
2. Could an EGR valve sticking open for an excessive amount of time cause a build up of carbon in the manifold/swirl flap area and cause them to fail?
I really appreciate your time on this, as I have had so many problems and so little answers.