1.6Hdi Mk2 Egr Issues And Fix

[Smerflet]

My 2007 Mk2 Estate was hesitating on acceleration and yielding pretty poor mpg. I finally bit the bullet and fitted a cheapo eBay replacement EGR valve which, I thought, had fixed the problem, however the problem returned. But each time I fiddled with the electrical connection the problem seemed to go away for a while but then recur.

 

I examined both ends of the electrical connection and they looked fine. As is the way with 'cheapos' the loom connector didn't quite fit so crisply into the EGR valve as that originally fitted, but I thought it was good enough. I cleaned them as best I could, then applied Nyogel 760 electrical contact grease (highly recommended) but still the problem kept coming back. Finally in desperation I gave each flat pin on the EGR valve connector a slight twist with snipe-nosed pliers, and this seems to have done the trick. I can only assume that one or more of the spring contacts in the loom connector has slackened with age and was not gripping the pin with sufficient force to maintain a reliable electrical connection.

 

Obviously don't go too far with the twisting, otherwise you might shear the pin off. But it worked for me.

 

Hope this helps.