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Thanks Paul

I think I can safely report the problem is resolved. I've fitted the new cat and it's now driving better than ever. I haven't done many miles yet as I've bought an after market cat and it's not a great fit. I'll be sorting that today and hopefully have my van back in service and ready for work on Monday. Thank you all again for your help and advice 👌

I meant to say I'n not receiveing notifications via email. I do get them in message centre.

I think I've selected the right options but I'm not receiving any notifications. I presume I'm missing a trick?

Thanks Paul, me too 😀 Thanks to you and everyone else for your help and suggestions. What a great forum this is. I've ordered a replacement cat so hopefully I'll be able to report the outcome by the end of this week.

Thanks again Paul. I tried to use the van this morning but could only just get to 30mph. I then discovered it would only rev to less than 3k revs even sat on the driveway. Prompted by previous feedback I disconnected the EGR from the manifold so exhaust gases could escape and amazingly it revs perfectly. I removed the exhaust and discovered the cat had loose black matting which has obviously been obstructing the exhaust system. It revs beautifully with no exhaust, although I doubt the neighbours were too pleased 😊 So I think I've solved it. Just need to go and order a new cat (it's too noisy to drive to an exhaust centre) and I will update you when I've tested it.

I managed to remove No.1 injector with a bit of messing about but it's fine anyway. Meanwhile the engine is slowly getting worse again â˜¹ï¸ I give up, time to get a new van.

Latest update: I haven't tried the crank sensor yet (is there a way to test it?). I was convincing myself the fault lay with the emissions control system so this morning I blocked off the EGR. At first there was loads of black smoke which cleared after a few miles, although I still get it at odd times but always under load. The power has increased but it's still not right, I would estimate I'm still only getting around 80/85% of the power it had before the EGR packed in. Couple of questions to my knowledgeable Citroen friends: 1.What is the device attached to the battery tray that connects via vacuum tubes to the EGR? I don't know what it does but if I disconnect the connector I get the standard malfunction light (engine block symbol). 2. How do you remove the injector at the flywheel end (no 1?). There is an electrical connection to it which prevents me using a socket and there is no room for a spanner. What is the purpose of this connector?

Yes the light illuminates at start up so it is working. I don't know if the exhaust is blocked and can't think of a way to check. I suspect it isn't as what would block it so suddenly? It has no problem pushing out the smoke when it's under load 😀 I have noticed today it has improved a little and I can get up to 60mph on the flat but less than 40mph on a climb. I've also discovered the air manifold box is badly gunked up from when the EGR failed but also the four seals are perished and almost non-existent so I've ordered a second hand replacement. I also checked the MAF with a multimeter and it is working, ie the voltage output increases with revs.

Paul H. I've tried two different MAFs, one a cheap copy, the other a branded one (I forget the make but a good one). Unplugging the MAF makes no difference but oddly when it's unplugged I don't get any fault lights either.

Too late 😊 but thank you for the advice. I've now confirmed the valve timing was spot on. The last time I did the valve timing on a Citroen was on a '92 diesel and it took me around an hour. Looking at the Berlingo manual it appeared to be pretty much identical so undaunted I pressed on. Four hours later I was finished! Everything is so much less accessible on a Berlingo 😊 I have tried driving to clear out any gunge and I've covered about 50 miles at a guess. It runs ok on low revs on flat roads, but try to accelerate to keep up with the flow or hit a hill and it's all over - no power and if I try to push it then I get lots of grey smoke and the temperature starts to climb. The signs point to a failed turbo but as it hasn't got one... The garage did run dianostic software which only identified a faulty MAF and EGR (both now replaced) but apparently everything else was normal. Next step is to try the injectors, although I don't think that's the problem as it feels like all four cylinders are flat rather that one limping along.

Latest update - still not good enough. The misfire has gone but the lack of power means I can't get above 30mph on a hill even with a run up. I'm suspecting the timing belt has slipped a notch, which wouldn't be surprising after the severe lurching of the previous misfire. So if the weather is dry tomorrow that's what I'll be looking at. Coastline, I have tried injector cleaner but it had zero impact â˜¹ï¸ I WILL fix this and I will report my findings here as it's intriguing and may even help someone else at some point.

I had a similar issue on my 2006 Relay except with 5th gear. I can't remember the details as it was a couple of years ago but I put it up on ramps and found the linkages had siezed up. I can't remember if I had to strip it or simply work it while applying oil, but I do remember it took a lot of force to get it moving at first.

The new EGR arrived today and I now have a driveable van again. It's not perfect as it's lacking power, especially under load such as climbing a hill. As it was so bad with the faulty RGR I suspect it may have gunked up an injector. I'll try taking it for a longer drive to see if that help clear it.