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