How-To Fix the EGR Valve on an 1.9JTD - PDF Instructions - Alfa Romeo Forum
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(Post Link) post #1 of 89 Old 14-04-10 Thread Starter
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How-To Fix the EGR Valve on an 1.9JTD - PDF Instructions

I have created a PDF manual with step by step photos and procedures for fixing a EGR valve on a 1.9JTD.

This how-to may be applicable for other Alfa / Fiat, Opel, Vauxhall and Saab Diesels with the same or similar EGR valve.

Please download from the link below.


How-to Fix the EGR on a 1.9JTD.pdf

http://sdrv.ms/NllzYU

ShiftyBloke
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Last edited by ShiftyBloke; 24-08-12 at 14:45. Reason: Added Skydrive Link
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Nice work, thanks for that!
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So there's no gasket between the valve and the inlet manifold then ? I've noticed my car is sluggish and produces smoke for a short time after a cold start, is this likely to be the EGR ? The smoke smells diesely rather than oily.
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Quality post! Photos really do make a difference.
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Excellent post, well done and thanks
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Quote:
Originally Posted by Alexie View Post
So there's no gasket between the valve and the inlet manifold then ? I've noticed my car is sluggish and produces smoke for a short time after a cold start, is this likely to be the EGR ? The smoke smells diesely rather than oily.
There are two gaskets - or at least I had two when I took mine off.

From the write up there is a larger oblong gasket missed out.

Last edited by CJO; 14-04-10 at 21:41.
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(Post Link) post #7 of 89 Old 15-04-10 Thread Starter
Status: vacuum issue.. help!
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There was definatley no gasket between the EGR and the manifold. I've had the car from new, and removed it once before, I was supprised then there was no gasket..

Oh well..

SB
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Very useful guide thanks!
Is a faulty EGR likely to cause high boost pressure? That is what's been diagnosed at high revs.
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Very useful guide thanks!
Is a faulty EGR likely to cause high boost pressure? That is what's been diagnosed at high revs.
Nope, In my experience High boost presure is sticking veins in the Turbo..

You will get the "I can move the actuator bar when the car is idling" form the engineers "so it can't be sticking" , but in my experience, when the exhaust is hundreds of degress oC through the turbo, the veins jam due to heat AND corrosion so that the VNT solinoid and actuator can't bring the veins back in to lower the boost pressure at high RPM's.

SB
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Nope, In my experience High boost presure is sticking veins in the Turbo..

You will get the "I can move the actuator bar when the car is idling" form the engineers "so it can't be sticking" , but in my experience, when the exhaust is hundreds of degress oC through the turbo, the veins jam due to heat AND corrosion so that the VNT solinoid and actuator can't bring the veins back in to lower the boost pressure at high RPM's.

SB
Is there a way to cure this?
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Is there a way to cure this?
It's involves removing the turbo, taking it apart, cleaning it out, prime with oil, re-assemble and refit.

I paid for an hour or two's labour..

I have seem a chemical way, which involves filling it up with a solution to breakdown the dirt and grime, and cleaning it out, but a manual approach i think is the best.

Check for split vacuum pipes and operation of the VNT solinoid too... (oh and the actual actuator)

SB
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Xylene is great for cleaning the sticky black gunk out of egr valves etc.

It's available in gallons on eBay (as a printers' solvent), or it's one of the 2 constituents of Wynn's carb/injector cleaner.
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Quote:
Originally Posted by ShiftyBloke View Post
It's involves removing the turbo, taking it apart, cleaning it out, prime with oil, re-assemble and refit.

I paid for an hour or two's labour..

I have seem a chemical way, which involves filling it up with a solution to breakdown the dirt and grime, and cleaning it out, but a manual approach i think is the best.

Check for split vacuum pipes and operation of the VNT solinoid too... (oh and the actual actuator)

SB
Hi Shiftybloke,

Where did you get this work done as I've same problem myself.

Cheers
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(Post Link) post #14 of 89 Old 21-04-10 Thread Starter
Status: vacuum issue.. help!
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Hi Shiftybloke,

Where did you get this work done as I've same problem myself.

Cheers
It was a Fiat Dealer / Merc dealer on the A2 in Kent, they've gone bust now Can't think why..
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Shifty bloke,

Just used your guide, 'How to fix the EGR' and i'm delighted to report a total success. The mechanical part of the valve was ok apart from the expected sooty deposits but the solenoid was stuck. Cleaned it and lubed it with silicone spray grease. Took the car out of the garage and it took off. I'm now suspecting that the valve has not been working properly for a lot longer than i thought and i'd just noticed when it got really bad.

Cheers mate,

Robert G.
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This thread should be made a sticky! Also, someone should set up a PayPal account which everyone who has used this guide pays £1 into ('if I had £1 everytime...') which goes to Shifty as thanks for the copious amounts of cash he has saved them.

I used this guide a couple of weeks ago to sort out my stuck EGR. Also fitted the restrictor gaskets when refitting the valve.

I've also had a couple of transient 'high boost pressure' error codes so I suspect the sticky turbo vains too...
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(Post Link) post #17 of 89 Old 29-01-11 Thread Starter
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Always a pleasure!! Glad to see people are finding and using the guide!!



SB
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First time I've seen this thread. Great work.
Many thanks.
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Thanks for the post I have been pulling my hair out over this & there is not enough to lose.
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This REAAAALLLY needs to be a sticky - plus can the title be modded to say 1.9 16v / 2.4 20v

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Hmmm Egrrrrrrrrrrrrrrrrrr!

HI Shifty Bloke

Great instructions, My 1.9 jtd is randomly losing power (usually after pottering around town then setting off at lights) and comes up with the mcsf warning at the same time, read up about it, disconnected maf sensor but still same so i know its not that, it regains power if you rev it to 3000 and mscf temporarily clears.
I took egr valve off and cleaned it out with carb cleaner and wd40 the whole valve and down the selenoid (i hadnt found your instructions at this point!). It sorted the problem for about a week or so, ran like a dream, but same symptoms have returned as bad as ever.
Should i take it off and strip down selenoid (didnt do that last time) the outer part seems to move freely with a little pressure, buy a new one or am i barking up the wrong tree altogether?
Any suggestions would be most appreciated
Thanks
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great work. Saved it for future reference.

If the inlet manifold is gunked up too ...apart from just scraping away at it ....is there anything that you could spray inside it to get rid of the soot -without taking it apart, obviously!
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EGR removal video

Hi Guys,
I'm hoping to change the egr, found this video that seems to compliment ShiftyBloke's guide. Shows how to avoid loosing gaskets etc

‪demontage EGR Alfa 147/GT/Fiat stilo jtd 16v‬‏ - YouTube
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Thanks for this, i'll be sure to do this to mine when I pick it up sometime this week
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I've added this thread to the 147/156 & GT how to thread.
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