Ok well I didnt go as far as removing the whole EGR valve as that involves new gaskets I think plus undoing a few bolts that were so tight I nearly rounded one off with a torque wrench! Need a proper hex socket rather than the spline ones. I will update this thread when I get the chance to fully remove it...
Engine off. EGR valve unplugged. Undo the 4 screw on the top of the valve (you'll where it's located in the next two pics):
Pic.1
Pic.2
When you lift off the top plastic motor that controls the valve this is what you'll see:
Pic.3
Then when you take off the metal block it's this:
Pic.4
Basically what I did was get a cloth and lots of clutch cleaner and sprayed it everywhere in the valve. Pushing the valve up and down via the circle of metal on a spring in the last pic there. Be careful when reassembling that the metal hooks (pic.3) fix correctly over the disc in pic.4.
Inlet Manifold Cleaning & underside of EGR valve
The way to get to the underside without removing the whole thing is to use Wynns Aerosol EGR cleaner. It cleans the inside of the intake manifold too which can get very caked up with soot and gunk from the exhaust getting pumped through.
Here's what it can look like without cleaning
and I'd imagine the EGR valve can get equally caked up. To use the spray download the instructions on Wynns website. Aerosol cans go for about £6 and are well worth it. To see which pipe to remove to then spray in the EGR cleaner, see the images after the dirty pics.
On a VW:
Cleaning the Inlet manifold with EGR spray cleaner.
Please note this pictures relate to a DCi in an Almera but the principle is the same.
To use the spray download the instructions on Wynns website -
http://www.wynns.be/index.php/en/x/30?cId=3&bId=233&pId=23379
Alternatively the instructions are attached to this post.
This is the rubber pipe you need to remove. Get the can down into the gap, with the nozzle at the top, and spray into the metal inlet manifold, following the directions as in the downloaded instructions.
WYNNS DIRECTIONS
Wynn´s Exhaust Gas Recirculation 3 is an aerosol product developed for cleaning the air intake system of all diesel engines.
Ref. Nr. 23379: 12 x 200ml
Properties
* Provides immediate thorough cleaning of air intake system, inlet valves, EGR valve and connecting tube between EGR valve and air intake manifold.
* Strong power jet spray to support cleaning action.
* Dissolves gum, lacquer, tar, carbon and deposits.
* Easy to use, cleaning takes only 5 to 10 minutes, with a minimum necessity to dismantle components.
* Restores perfect air flow towards the combustion chamber.
* Provides a regular and stable idle.
* Restores or maintains the engine performance and fuel consumption.
* Eliminates and avoids starting problems.
* Improves accelerating properties.
* Reduces black exhaust emissions.
Applications
* For the air intake manifold, inlet valves and EGR valve of all diesel engines.
* Also recommended to be used at each service interval to maintain cleanliness.
* Possibility to use an extension spray tube with multiple injection holes (option).
* Do not spray on painted surfaces. In such case, immediately clean with water to prevent damage.
Directions
* Cleaning of air intake manifold and inlet valves.
* Start the engine until its warm.
* Remove the flexible hose in the air intake system, situated between the turbocharger/intercooler and the air intake manifold.
* Let engine run at 2000 rpm.
* Spray the product, with short intervals, into the air intake manifold.
* Rpm and diesel knocking can rise during pulverization.
* After each pulverization, wait until original set rpm is regained.
* If necessary accelerate to avoid engine stalling.
* Continue until the 200 ml of product in the aerosol are consumed.
* Let the engine run at idle during a few minutes.
* After this idling period, accelerate the engine approximately 5 to 10 times or drive 5 to 10 km.
* Do not exceed 3000 rpm.
* Stop the engine.
* Put hose back in place.
Packaging Languages
EN/FR/DE/ES/IT/NL/RU/EL
