The complete guide to EGR cleaning (1.6HDi and 1.6TDCi engines)

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.

Here are the components that I used:

All my car-related purchases: https://www.amazon.co.uk/shop/moremolecules

The replacement EGR valve that I used was HELLA (https://amzn.to/2MJFLFm).
The Clic-R tool to undo the clic-r clamp, Draper 89791 (https://amzn.to/2pl6Oi5).
The replacement EGR clic-r clamp that I used for easier removal in future: https://amzn.to/2prXicU (Peugeot/Citroen part number: 1628 3J)
The Diesel Fuel Filter: Delphi HDF939 (https://amzn.to/2ORSsR1) or a Bosch filter will also work: https://amzn.to/2MhCbTE
The water in diesel sensor with Peugeot/Citroen part number: 191311
EGR valve bolts Peugeot/Citroen part number: 162793
14 pcs E Star Torx Socket Set for the EGR valve bolts: https://amzn.to/2oM4ZuD
Wynn's Carburettor cleaner: https://amzn.to/2MKWjwr
Wynn's Diesel EGR valve cleaner: https://amzn.to/33xTaHh
My torque wrench (2-24Nm): https://amzn.to/33xTc1R

00:00 - Introduction
00:36 - Overview of the 1.6HDi engine
01:00 - Removal of various air intake pipes
03:30 - Unclip MAF sensor
04:00 - Uncliphe crankcase breather
05:45 - crankcase breather (PCV valve) o-ring
06:18 - Remove air filter box
08:50 - Remove Fuel (diesel) filter
13:44 - Water in fuel (diesel) sensor location
14:21 - Remove fuel filter bracket
15:02 - First view of the EGR valve
15:18 - Location of EGR gasket
16:11 - Original clic-r EGR clamp + tool to remove it
17:31 - Replacement clic-r clamp, better design
18:04 - Remove clic-r EGR clamp
19:30 - Unscrew the two EGR valve bolts
23:42 - EGR valve is out!
24:14 - First look at the carbon build up in the EGR valve
26:10 - Taking the top part of the EGR valve
27:45 - A view of the EGR valve channel and rotating pin
31:50 - The actual cleaning of the EGR valve with Wynn's Carburettor cleaner
32:28 - The EGR valve is spotless!
33:44 - Taking apart the electronic part of the EGR valve
35:47 - Putting back the top (electronic) part of the EGR valve
38:10 - Putting back together the whole EGR valve
40:54 - Putting the EGR valve back in
45:25 - Putting the fuel filter bracket
46:03 - Putting the fuel filter back
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

Several helpful videos:
How to fix oil dripping from the crankcase breather (https://www.youtube.com/watch?v=ziKR6M6ToSg)
Fix rattling air filter box (https://www.youtube.com/watch?v=qBNSyRF79VQ)
Fit a water in diesel/fuel sensor (https://www.youtube.com/watch?v=-ZqiyCFg0sI)
Clic-r tool with the original clamp (https://youtu.be/GdsexBbxW44?t=326)
taking apart an EGR valve (https://www.youtube.com/watch?v=kuAfI1QbGAw)
NaOH/KOH and Aluminium (https://www.youtube.com/watch?v=4O3fOHYBXx0)
Assemble the electronic part of an EGR valve (https://www.youtube.com/watch?v=skYgkb4xSbQ)

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; 9HXC engine). 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, I am just cleaning the EGR valve as part of my car maintenance. Nevertheless, with a faulty EGR valve you may get some of these error codes: P0490, P1162, P0401 and P0409. Faulty EGR may happen to be completely shut or open.

This is a replacement EGR valve. I replaced my original EGR valve ~1 year and 8 months ago. I have travelled ~20,000 miles or ~32,200 km 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 or KOH. These react with the aluminium in the EGR valve and will dissolve it.

The whole process of cleaning the EGR valve does not take too much time, I would say ~2-3h all in all, if you have the tools and the tool to unlock the clic-r clamp that holds the EGR valve to the intercooler.

For the EGR bolts I used ~10-12Nm torque. Same for the bolts for the diesel fuel filter bracket.

#HDi #EGR #CarMaintenance

Disclaimer: Use the information provided in this video at Your Own Risk. More molecules provides this video for informational purposes only and assumes no liability for any damage or loss incurred as a result of the use of the information or tools presented in this video. The information provided here may contain inaccuracies and more molecules cannot guarantee the correctness or reliability of the content.
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Видео The complete guide to EGR cleaning (1.6HDi and 1.6TDCi engines) канала more molecules