Putting in new EGR valve 2.0hdi mk1

victorlohe · 2025-08-13 21:27:17

Hi

I’ve gone 3 days now tinkering on how to do this the easiest, or if it’s even possible?

The EGR is placed as bad as it could be, has anyone changed it? Tips and tricks are well appreciated, what sizes are the bolts?

Thanks!

Hammersfixeverything · 2025-08-15 20:44:32

You can have it blanked off and mapped out, I think I seen places do for about £180. Thats what I plan to do when my fails, but it is a 1.9D

kenbw2 · 2025-08-16 01:53:43

Hammersfixeverything wrote:

but it is a 1.9D

The EGR on the 1.9D DW8 is insanely easy to access - it's right at the front unlike the XUDs and HDis

JohnDragonMan · 2025-08-25 21:09:55

i "serviced" my EGR valve on my HDi. it is very easy to do, you just have to remove the air filter housing if you want to permanently "fix" it. the kits are available cheaply on a well known auctioning site. on newer vans than a mk3 (newer than 2007) you would have to get it remapped also but on anything older it does not know its been "permanently repaired". wink

Last edited by JohnDragonMan (2025-08-25 21:12:27)

you-wont-believe-it · 2025-12-04 19:56:24

i dont understand re easy to get to the egr valve on 2.0hdi it is at the left hand upper rear of engine.
i have tried the spray in egr cleaner but that didnt seem to make any difference
i have a 2000 with a 2.0hdi
it had 24k from new how ever
ive had variouse problems and still do
right from the start it was difficult to start
that was the starter motor not quite powerful enough.

then limp mode, i believe that was the egr valve
im close to having an attemp at changing or cleaning it. its very difficult to get at it
one fault was
the fuel and temp went to full and the engine off red light came on
the engine was cutting out but starting its self straight away. this fault damaged the crankshaft rubber i managed to weld the crankshaft back together to get home then
i changed that.
i also fitted a new crank sensor
AND
took the auto fuel cut out switch off
this is a black unit with a red rubber cap. its meant to cut the fuel supply in an accident
i cleaned it and put it back
the engine wouldnt start
i pushed the middle red bit back down and the engine started fine

i think the ball bearing can get rusty and the two metal blade contacts can corrode, causing the switch to cut the fuel !

anyway
i renewed the fuel pump relay
and stripped out all the wirering between the ECU across the front of the engine to the fuses and relays but found no damaged wires
but it kept cutting out until i fitted the new crank sensor/ and or stripped and cleaned the accident fuel cut off valve
trouble is i did both at the same time so which was the cause.

so back to the present
van now has just over 40k

starts spot on
orange engine light comes on and goes off when it decides to
the light will normally come on if i give it higher revs

next fault is

until the revs get up the engine is sluggish
then as it reaches a certain rev range away it goes, just like hitting a power band

as i said im going to work on van over next few weeks

first job is egr, i shall do or shall i say attempt to do it from under the van with quarter drive sockets
but suggestions after that please
im ready to change the timing belt but.just incase any one has had issues re crank shaft and the movement to.micro ajust the timing. as it stands i only have the engine locking tools
has any one checked the timing on this engine with out the fancy gauge

cheers
mick

Last edited by you-wont-believe-it (2025-12-15 21:50:39)

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#1 2025-08-13 21:27:17

Putting in new EGR valve 2.0hdi mk1

#2 2025-08-15 20:44:32

Re: Putting in new EGR valve 2.0hdi mk1

#3 2025-08-16 01:53:43

Re: Putting in new EGR valve 2.0hdi mk1

#4 2025-08-25 21:09:55

Re: Putting in new EGR valve 2.0hdi mk1

#5 2025-12-04 19:56:24

Re: Putting in new EGR valve 2.0hdi mk1

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