*Guide* Cleaning EGR Valve *UPDATED*

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*Guide* Cleaning EGR Valve *UPDATED*

Post by Octane2097 » Fri Dec 04, 2009 4:06 pm

!!DONT START THIS UNLESS YOU HAVE A REPLACMENT EGR VALVE GASKET AS A NEW ONE WILL BE REQUIRED!!

The EGR (exhaust gas recirculation) Valve recirculates emision to be futher burned off to reduce emission levels.
a gunked up one can cause problems like sticking/high revs irratic idle, lack of power at high revs
if you have attempted the ICV guide and still suffering with bad running could give this a try.

Cleaning the EGR Valve

The exhaust gas recirculation system, fitted to all engines except the 1.4 litre SOHC engine
with multi-point fuel injection its designed to recirculate small quantities
of exhaust gas into the inlet tract, and therefore into the combustion process.
This process reduces the level of oxides of nitrogen present in the final exhaust gas
which is released into the atmosphere.
The volume of exhaust gas recirculated is controlled by the ECU, via a valve mounted on the inlet manifold.

NOTE: you will need to drain some of the coolant out before starting.
NOTE: on 1.4 16v and 1.6 16v you will need to depressurise the fuel system

To drain the cooling system, first cover the expansion tank cap with a wad of rag, and
slowly turn the cap anti·clockwise to relieve the pressure in the cooling system (a hissing sound will normally be heard).
Wait until any pressure remaining in the system is released,
then continue to turn the cap until it can be removed.
Position a suitable container beneath the radiator bottom hose connection, then slacken the hose clip and ease the hose from the radiator stub.
lf the hose joint has not
been disturbed for some time, it will be necessary to gently manipulate the hose to break the joint.
Do not use excessive force, or the radiator stub could be damaged.
Allow the coolant to drain into the container.

To Depressurise the Fuel System (For 1.4 16v and 1.6 16v engines only)
Disconnect the battery negative terminal first, make sure it cannot connect to anything and possibly spark!
Place a container beneath the connection/union you want to disconnect (id reccomend at the fuel tank or fuel filter)
have a large rag ready to soak up any escaping fuel not being caught by the container.
Slowly loosen the connection or union nut to avoid a sudden release of pressure, and position the rag around the connection, to catch any fuel spray which may be expelled.
Once the pressure is released, disconnect the fuel line.
and plug the pipe ends, to minimise fuel loss and prevent the entry of dirt into the fuel system.

1.0 and 1.2 litre DOHC engines

NOTE: you will need to drain some of the coolant out before starting.

The valve is located at the left-hand end of the cylinder head.
Disconnect the battery negative terminal
Partially drain the cooling system as some coolant may leak out
then disconnect the coolant hose from the rear of the EGR valve housing
Disconnect the wiring plug from the top of the EGR valve and the wiring connector from the adjacent temperature gauge sender.
Move the wiring harness to one side for access to the EGR valve housing mounting bolts.
On 1.2 litre engines, undo the two bolts securing the EGR pipe to the side of the EGR valve housing
Undo the four bolts securing the EGR valve houslng to the cylinder head and withdraw the
housing assembly
Thoroughly clean the mating faces of the
valve, cylinder head and EGR pipe flange,
then refit the valve and pipe
Dont forget to Top-up the cooling System!!

1.4 and 1.6 litre DOHC engines

NOTE: you will need to drain some of the coolant out before starting.
NOTE: on 1.4 16v and 1.6 16v you will need to depressurise the fuel system

Depressurise the fuel system as first of all then Disconnect the battery negative terminal if not already done.
Then Partially drain the cooling system as coolent may leak out.
Disconnect the coolant hoses and remove the cooling system expansion tank.
Unscrew the union nuts and disconnect the fuel feed line from the fuel rail, and the return line from the fuel pressure regulator.
Undo the bolts securing the wiring trough and air inlet pipe from the inlet manifold lower section.
Detach the air inlet hoses at the inlet pipe and push the pipe downwards slightly for access to the EGR valve.
Disconnect the wiring plug from the valve.
Unscrew the two securing bolts, and withdraw the valve from the inlet manifold.
Check the valve vent holes for contamination, and clean if necessary.
Refitting is a reversal of removal.
Thoroughly clean the mating faces of the valve and manifold, then refit the valve
Dont forget to Top-up the cooling System!
and dont forget to reconnect the fuel system!!
Last edited by Octane2097 on Tue Apr 06, 2010 3:41 pm, edited 6 times in total.
Reason: Updated