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Replacement EGR valve 1.6D

Written By: xmod13 (and one other contributor)

Difficulty

Difficult

Steps

Time Required

03:00:00

Introduction

This tutorial explains how to change the EGR valve on a 1.6D engine.

Open the hood then start by removing the metal support protecting the diesel filter.
Loosen the 2 screws using an 8 socket
Loosen the 3rd screw using a 9 mm wrench.

Remove the 3 pipes by pressing the rectangular button on the end first.
Plug the pipes with a clean, lint-free cloth to prevent fuel from spilling onto the engine.
Remove the metal tab secured by two screws using an 8 socket (circled in purple).
Also disconnect the electrical connector on the fuel filter (circled in green)

Place caps on the filter pipes to avoid spilling any fuel contained inside when removing it.
Remove the fuel filter from the top, taking care not to damage any nearby electrical cables.
Remove the filter support by unscrewing the 2 screws using an 8 mm socket.

The valve is now accessible. Disconnect its electrical connector.
The valve is fixed by two screws (1 hidden in the photo) as well as by a collar fixed on the air inlet pipe
Start by unlocking the collar with the Clip R pliers
Then unscrew the two screws with a size 8 ring spanner (a ratchet ring spanner is recommended, given the limited accessibility)
Before completely removing the two screws, hold the EGR valve against the engine by hand to prevent the seal from falling out.

The valve and its metal seal are removed. Proceed to exchange the two elements.
Place the metal gasket in the direction recommended in the photo. Apply grease to the gasket and the valve plane so that it remains stuck to facilitate the installation of the valve.

Center the valve on the engine mount and insert its other end into the air/water exchanger piping
Insert the two fixing screws and tighten them with an 8 mm ring spanner.
This step is difficult because access is restricted and the metal seal can easily become crooked. Before fully tightening the screws, make sure that the seal is correctly positioned and secured by the screws.
Once the valve is fixed, lock the collar using the Clic R pliers
Connect the valve electrical connector.

Proceed to refit the diesel filter support, the filter, and the two upper metal supports in the reverse order to removal.
Clean the area with a cloth and degreaser
Start the engine for a few seconds and then turn it off. You will hear an electrical noise at the EGR valve for a few seconds. The computer is automatically learning the valve. This test is systematic and normal.