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Thread: Sometimes only a new EGR will do.....

  1. #1
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP1

    Engine : 1.9 CDTi 150

    Year : 2007

    Mileage : 66000

    Default Sometimes only a new EGR will do.....

    I thought I would post this up to provide some info and help others trace symptoms that they may be having on their cars.

    This weekend I helped a mate diagnose and cure a few problems he had been having with his CDTi (150 - 2005) he had been experiencing the following issues:


    • Lumpy tickover (worse when cold, but still apparent when warm).
    • A slight judder when switching engine off.
    • Sluggish under 2K rpm (getting worse by the week).
    • Sounding very 'diesely' and clattery.
    • Slight misfire between 1500 and 2000 rpm.

    We thought it would be the EGR, so he had bought a new one from eBay (Pentagon - £95) and bought the Fiat semi-blanking gasket. We removed the old EGR valve from the car and although being black inside was very clean considering, we separated it and the solenoid side was as clean as a whistle and the solenoid moved with ease - the spring on the other side was as free as anything too. At this point we were worried as couldn't see how this could be at fault - so we cleaned up the inlet manifold opening (again not much in ther to be honest) and went about fitting the new EGR and Fiat gasket. Once all done the split second the engine turned over we knew it had the desired effect - the lumpiness has totally gone, it was much quieter too - a quick test drive also showed the power to be back with a vengeance (he's just texted me after his commute and has further reiterated this).

    I am not saying that you cannot clean and fix an EGR valve (many posters have confirmed this works - and is the first course of action with the above symptoms), but I am posting this to say that if that has been done and the problems are still there then a new EGR is the only thing that will do

  2. #2
    Regular Member parsco's Avatar
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    Default

    I did exactly the same thing mate. Tried cleaning it first and it didn't really make much difference but and soon as I bolted a brand new one on it was spot on

  3. #3
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    Ive done my solenoid repairs as on here, but I still have that nag in my mind if a new one would make it any more perfect..Will be a decision I will make in the summer I think. Will see how my mods on my egr go, as the weather warms up.. I have cured the misfire, the hesitation and the judder at idle. But think the cars slowed up on its responsiveness just a little again in the last week from when the soleniod was cleaned and regreased two weeks ago and it flew like a banshee

  4. #4
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP1

    Engine : 1.9 CDTi 150

    Year : 2007

    Mileage : 66000

    Default

    Quote Originally Posted by hertscol View Post
    Ive done my solenoid repairs as on here, but I still have that nag in my mind if a new one would make it any more perfect..Will be a decision I will make in the summer I think. Will see how my mods on my egr go, as the weather warms up.. I have cured the misfire, the hesitation and the judder at idle. But think the cars slowed up on its responsiveness just a little again in the last week from when the soleniod was cleaned and regreased two weeks ago and it flew like a banshee
    Definately sounds like a new one is needed mate (recommend the Fiat gasket too).

    Just to re-iterate, the Fiat part number for the semi-blanking gasket is 55225287 and is £4.04 + VAT (but is usually an order in part from Italy).
    Last edited by Dan_BlackSRi; 15th February 2010 at 11:47. Reason: Added Gasket part number...

  5. #5
    Regular Member P3tchy's Avatar
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    Is that part number for the gasket going into EGR or going out into the manifold?

    Reason I ask is I put the one betwix the EGR and manifold on and it ran flat as pancake, then the EML came on, after a quick tech2 code read it showed as O2 sensor and EGR, i.e not enough gas flowing through. Removed the blanking plate and its been better since but still get.....

    Lumpy tickover (worse when cold, but still apparent when warm).
    A slight judder when switching engine off.
    Sluggish under 2K rpm (getting worse by the week).
    Sounding very 'diesely' and clattery.
    Slight misfire between 1500 and 2000 rpm.

  6. #6
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP1

    Engine : 1.9 CDTi 150

    Year : 2007

    Mileage : 66000

    Default

    Quote Originally Posted by P3tchy View Post
    Is that part number for the gasket going into EGR or going out into the manifold?

    Reason I ask is I put the one betwix the EGR and manifold on and it ran flat as pancake, then the EML came on, after a quick tech2 code read it showed as O2 sensor and EGR, i.e not enough gas flowing through. Removed the blanking plate and its been better since but still get.....

    Lumpy tickover (worse when cold, but still apparent when warm).
    A slight judder when switching engine off.
    Sluggish under 2K rpm (getting worse by the week).
    Sounding very 'diesely' and clattery.
    Slight misfire between 1500 and 2000 rpm.
    What did you fit..? A full blanking gasket..?

    The Fiat one has 4 holes in the centre to affect the airflow within the EGR (in effect to speed up the air going through it) in the inlet manifold. The gasket fits between the EGR and manifold.

    The red one pictured is the updated Fiat gasket......


  7. #7
    Regular Member P3tchy's Avatar
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    Mines the same as the silver one but without the red part.

  8. #8
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP1

    Engine : 1.9 CDTi 150

    Year : 2007

    Mileage : 66000

    Default

    Quote Originally Posted by P3tchy View Post
    Mines the same as the silver one but without the red part.
    Like the one above it (basically a metal plate).....?

    If so, they need the OE gaskets fitting either side as they don't create a good enough seal on their own.

  9. #9
    Regular Member P3tchy's Avatar
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    Yeah had the gaskets on as well, Took it off and it ran alot better, My mechanic is going to update the software on the ECU tonight to see if that cures it, and I'm gonna strip and rebuild the EGR.

  10. #10
    Regular Member Dan_BlackSRi's Avatar
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    Vehicle : Vectra SRi

    Trim : XP1

    Engine : 1.9 CDTi 150

    Year : 2007

    Mileage : 66000

    Default

    Very odd, as those Fiat gaskets have been widely used in the Fiat/Alfa community (and a few on here) with no problems at all...... must be a blockage in the EGR as it stands.

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