How to properly clean the EGR valve in 1.6HDi/TDCi engines. This is a complete guide with all steps included and taking the EGR valve completely apart. Timings are below.
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Here are the components that I used:
The replacement EGR valve that I used was HELLA (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
The Clic-R tool to undo the clic-r clamp, Draper 89791 (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
The replacement EGR clic-r clamp that I used for easier removal in future (amazon UK): [ Ссылка ] or ebay: [ Ссылка ] (Peugeot/Citroen part number: 1628 3J)
The Diesel Fuel Filter: Delphi HDF939 (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
The water in diesel sensor with Peugeot/Citroen part number: 191311 (ebay: [ Ссылка ])
EGR valve bolts Peugeot/Citroen part number: 162793 (ebay: [ Ссылка ])
14 pcs E Star Torx Socket Set for the EGR valve bolts (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
Wynn's Diesel EGR valve cleaner (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
My torque wrench (2-24Nm) (amazon UK): [ Ссылка ] or ebay: [ Ссылка ]
00:00 - Introduction
00:36 - Overview of the 1.6HDi
01:00 - Removal of air intake
03:30 - Unclip MAF
04:00 - Unclip crankcase breather
05:45 - crankcase breather (PCV valve) o-ring
06:18 - Remove air filter box
08:50 - Remove Fuel filter
13:44 - Water in fuel sensor
14:21 - Remove fuel filter bracket
15:02 - First view of the EGR
15:18 - Location of EGR gasket
16:11 - Original clic-r EGR clamp + tool to remove it
17:31 - Replacement clic-r clamp
18:04 - Remove clic-r EGR clamp
19:30 - Unscrew the two EGR valve bolts
23:42 - EGR is out!
24:14 - First look at the carbon build up in the EGR
26:10 - Taking the top part of the EGR
27:45 - A view of the EGR valve channel and rotating pin
31:50 - The actual cleaning of the EGR valve with cleaner
32:28 - The EGR is spotless!
33:44 - Taking apart the electronic part of the EGR
35:47 - Putting back the top (electronic) part of the EGR
38:10 - Putting back together the whole EGR
40:54 - Putting the EGR valve back in
45:25 - Putting the fuel filter bracket
46:03 - Putting the fuel filter
47:15 - Putting the air filter box back in
48:18 - Putting the air pipes back in
50:24 - Getting the air out of the fuel system
Helpful videos:
How to fix oil dripping from the crankcase breather ([ Ссылка ])
Fix rattling air filter box ([ Ссылка ])
Fit a water in diesel/fuel sensor ([ Ссылка ])
Clic-r tool with the original clamp ([ Ссылка ])
taking apart an EGR valve ([ Ссылка ])
Assemble the electronic part of an EGR valve ([ Ссылка ])
This video is a complete guide how to get to the EGR valve in 1.6HDi/TDCi engines. The car is a 1.6HDi Peugeot Partner 2007 (90bhp; M59). This is the same as Citroen Berlingo from the same year. This guide should be similar to other Peugeot and Citroen cars, also Ford 1.6TDCi, apart from the position of the airbox filter.
There were no errors, but with a faulty EGR valve you may get some of these error codes: P0490, P1162, P0401 and P0409.
This is a replacement EGR valve. I replaced my original EGR valve ~1.8 years ago and travelled ~20,000 miles since then. The carbon build up in the EGR valve is from this mileage.
When cleaning the EGR valve use carburettor cleaner or diesel EGR cleaner. Do not use oven cleaner. Oven cleaners will contain NaOH/KOH. These react with the aluminium in the EGR valve and will dissolve it.
The whole process of cleaning the EGR valve takes ~2-3h. 10-12Nm torque for EGR bolts and bolts for diesel fuel filter bracket.
#HDi #EGR #HDiEGR
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