159 Cruiser and
AO Silver Member
Join Date: Jul 2012
Location: United Kingdom
Greetings to Norway (just back from Oslo last night!)
This has been covered before (use search for a bit more info), but 4% is closed (it's the base value). One of the problems is the Pin in the EGR that opens and closes the valve (did you take that bit of the EGR apart?), it corrodes in it's housing and won't move properly, as a result the car is demanding it be closed, but it just sticks open. Not a lot you can do if it is coroded, but you can replace the EGR (pick up a new one for £80 on ebay (its the same as the one in Opel CDTI, or Saabs). But double check the EGR is the issue by blanking it temporarily with some metal (the side of a drinks can will do for a couple of hundred mile (only!!!!)). It will raise a warning light on the dash (that will disappear after 3/4 starts (with key removed between) when its removed).
Long term you will probably need a new EGR, at least get a restrictor plate, but for the price of £150 Autolusso will blank and remove from the ECu (if you have the time, you can send off the ECU to them to do it).
Also if you have an EGR issue, then you may have a clogged DPF, ensure you give it a good run. (otherwise check the diesel power loss guide in the stickies)
159 1.9JTDM Ti and Giulietta 2.0 Veloce
ex: Punto 55s, Golf Mk5 1.4FSi, A3 (8P) Sportback 2.0TDi SE, A4 (B8) 2.0TDI S-Line, 306 HDI Meridian