Sticky EGR valves

[xsara92]

Wondering if anyone has experience of a misbehaving EGR valve with PSA diesel engines (esp HDi 16v).

Mine has been diagnosed as causing tugging back at a range of conditions but most often when accelerating uphill at 40-50mph.

I would look at replacing the EGR myself but with the Xsara Picasso, the brake fluid reservoir obscuring access to the air filter which needs removal puts me off...my local garage quoted 2 1/2 or 3 hours work plus parts.

If this kind of intermittent EGR valve always increases the emissions from the engine (especially by making the engine dirty if it's 'too often open') then I would pay for the repair without fail, as I want the car to run.

Anyone's knowledge and experience would be appreciated.

Cheers

[wheeler]

If i remember right the brake fluid reservoir is just held on with 2 torx screws, you can undo them & move it out the way without draining the fluid.

[RichardW]

That was pretty much the symptoms we had on our C4 Picasso which needed EGR replacement. It's not as bad as it looks, may have to remove the windscreen scuttle to get access.

[Steve Walsh]

if you remove scuttle, and put a big thick blanket over engine to lean on, makes it a much easier job...

[moizeau]

My van did this after changing the EGR. It was the MAF. Unplug it and see if the condition improves.

[xsara92]

Thanks to those who replied above.
I should have added that I've no experience fixing things but I hope to get a backup car at some point (hopefully with the same engine).
What is people's experience of a failing EGR valve? I really can't discern anything getting worse in my case....I should have added that I have the infamous rattly old air box that afflicts HDi engines. It is claimed that if this is bad enough, the airbox can actually foul the EGR momentarily I think...sounds plausible but I'm no expert

[malc4]

My experience with EGR started with esp/asr warning light with various egr related codes eg P0489/P1162.
Removing it was a tricky as it was stuck. Managed to break the plastic housing. Condition of valve didn't look too bad- not too much carbon build up.
Fitted replacement valve from scrappy- error codes returned. Eventually tracked it down to a short inside the connector. Spliced in new connector and valve now behaving itself. Looking at live data should indicate whether problem is electrical or mechanical.

[xsara92]

Interestingly, I thought I had an ESP/ASR fault initially because it was on bends that I generally experienced the symptoms - but I never got a warning light and my ESP I eventually discovered is working fine.

[malc4]

I've also just had esp/asr lights triggered by low fuel pressure codes (blocked fuel filter i think)..

[malc4]

1.6 Hdi 16v EGR looks slightly less accessible/fiddly than my 8v but nothing to get stuck (mine inserts into the manifold, yours just bolted on with gasket?)
Lots of vids on utube. I'd be looking at live data first tho..

[xsara92]

I've tried to upload a picture of the area of the engine on my car where I understand the EGR to be.

[Steve Walsh]

remove plastic air pipes and air filter / air filter housing and it will be visible over back of engine, Been a while since I did a 1.6 and can't remember exactly but not too difficult

[xsara92]

Does anyone have a good source on how electrically operated EGRs function?
My Haynes manual claims that the 1.6HDi on the Xsara P is electrically operated, some early valves were vacuum driven.
I thought that the principle of operation of an EGR was opening/closing at a rate, but it if it is based on a continuous position, it makes me more minded that mine could be stuck too far closed, I.e. less EGR than designed - and this could gunk up my engine over time. If it was the other way round, surely I would have performance issues but the engine is quiet and not lumpy at idle and I get no EML.

[xsara92]

Also anyone know roughly how many and what tools are needed for the plastic pipes and other ancillaries in the way, on the Xsara Pic? Many thanks

[PaulC5]

Have you asked a dealer how much they will charge to replace the egr valve to give you a guide on how much you will save diy if you are having to buy tools ?