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Author Topic: Seat Alhambra EGR valve problem (again)...  (Read 1154 times)

Offline stakhanov

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  • Posts: 15
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  • Model: Alhambra Mk2
  • Spec: SE TDI 2010
  • First Name: Andrew
  • Region: South East
  • Country: United Kingdom
Seat Alhambra EGR valve problem (again)...
« on: February 11, 2019, 07:44:17 PM »
I had a problem with the EGR valve on my Seat Alhambra last April (2018) which I managed to solve by removing and cleaning out. Link below:

https://www.fordmpv.com/smf2/ford-galaxy-vw-sharan-seat-alhambra/advice-needed-on-egrthrottle-body-problem/

That worked fine for a while but since then (probably after about 5 months), I started getting the same symptoms (intermittent drop in revs, almost like foot slipping slightly on accelerator). Eventually the car engine stopped, so took EGR valve off again. It was gunked up again, so cleaned it all up again. I noticed that the plunger felt a bit stiffer than it had previously, even after cleaning thoroughly.

Since that time, after initially being fine, I am getting the symptoms again. I can't imagine it clogging up so quickly is normal, but my question is:

1. Is this likely to be a faulty EGR valve, with the plunger not operating correctly causing it to clog up and seal shut?
2. Is it possible that something else is wrong in the engine, causing an excess of soot to build up and speed up the clogging of a perfectly fine EGR?
3. If 2 is possible, I have to consider a combination of 1 and 2 could be happening.

I'd be happy to just replace the valve, but would like to know the likelihood of this fixing the problem. I have found a pretty cheap one here:

https://www.ebay.co.uk/p/Genuine-Wahler-EGR-Valve-Gasket-7529D-Seat-ALHAMBRA-7v-2-0-TDI-2005-10/1163268505?iid=181859904249&chn=ps

Alternatively, I'd be happy to blank it off. However, all EGR blanking plates that I can find online are for a different type of EGR. My particular type seems to be fairly uncommon on Alhambras (see first post linked above to see pictures).

Advice would be appreciated.


Offline johnnyroper

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  • Posts: 2858
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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #1 on: February 11, 2019, 11:48:16 PM »
You have a type that is not as easy to blank as the earlier 1.9, fairly easy to make a blank plate to block it manifold end and stop crap from exhaust entering but it will trigger an engine light. It will need programming out with software to sort it properly.

Offline stakhanov

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  • Posts: 15
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: SE TDI 2010
  • First Name: Andrew
  • Region: South East
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #2 on: February 12, 2019, 07:11:09 PM »
I'm still trying to get my head around how the EGR works. There is open and shut (and, I guess, a continuum of states in between), but does that mean open to let the exhaust gas recirculate, or open to let the exhaust gas escape through the exhaust system? So when you fit a blanking plate to the simpler version, is this effectively leaving the valve permanently open, or permanently closed (I assume it' leaves it open, as when mine was clogged shut, it caused the engine problems)?

If it is as simple as that, could I not just remove the valve arm (chop it off if necessary) and refit the valve housing, leaving the valve permanently open? Why does it need a plate?

As for needing to program out the engine management light, is that a massive job? Is something I could just ask my garage to do when it goes for MOT next?

Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #3 on: February 12, 2019, 09:54:49 PM »
Valve is normally closed stopping exhaust gas entering the inlet,when ECU demands egr valve opens and lets in exhaust gasses to be re burnt.
When you blank off you basically blank the port on the exhaust manifold so gasses cannot enter the valve.

Itís not a big job mapping it out just a case of getting a mapper to plug laptop in and adjust some software,no idea what it would cost on yours though. I had a 1.9 Alfa 159 that I blanked and mapped out. Bought a kit for £150 which included the blanking plates,diagnostic lead and some software the software allowed an ECU read which was emailed to a company they adjusted the map and sent back for me to load back on. Not sure if there are options like this for VW bit a google search should throw up some options.

Offline stakhanov

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  • Posts: 15
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  • Model: Alhambra Mk2
  • Spec: SE TDI 2010
  • First Name: Andrew
  • Region: South East
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #4 on: February 12, 2019, 10:36:26 PM »
Hmm, well that's not what I expected. Can't understand then why my engine didn't like the EGR valve being clogged shut. What's the difference between that and a blanking plate?

Will think on what's best to do next. Thanks for the advice (again).

Online brianh

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  • Model: Galaxy Mk2
  • Spec: 2001 2.3 Ghia LPG
  • First Name: Brian
  • Region: South East
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #5 on: February 13, 2019, 12:20:52 AM »
Not on a Alhambra, but have had a blocked dpf on an espace cause far too much to come back around the egr circuit and cause problems. Combination of blanking off egr, dpf cleaner, long runs at motorway speed and fixing dpf sensor hoses eventually fixed it.

Biggest clue something was up was the amount of smoke that came out of the egr pipe when disconnected and tried to start - it would start and run like that, but had something like a smoke cannon going for a couple of minutes afterwards.

Offline johnnyroper

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  • Posts: 2858
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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Seat Alhambra EGR valve problem (again)...
« Reply #6 on: February 13, 2019, 07:50:04 AM »
Hmm, well that's not what I expected. Can't understand then why my engine didn't like the EGR valve being clogged shut. What's the difference between that and a blanking plate?

Will think on what's best to do next. Thanks for the advice (again).

Could either be it was clogged but partially open still,I have a Lexus that had exactly that last week it caused problems starting and severe lack of power. Or the ECU has thrown a wobble after valve fails to move when commanded.

Offline mike wilson

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  • Spec: mondeo mkIV 1.8
  • Region: North East
Re: Seat Alhambra EGR valve problem (again)...
« Reply #7 on: February 14, 2019, 09:59:54 AM »
As above, the EGR is normally only open at low revs and cold engine.  This both allows for a quicker warmup and reburns exhaust which is loaded with unburnt hydrocarbons from rich cold mixture, thereby reducing air pollution.  If you do mostly short journeys where the engine does not warm up fully, the valve may stick slightly open due to carbon build up, causing higher quantities of exhaust gas to recirculate.  There may also be an issue with, for example, oil leaks from the turbo.

There are only two solutions. Firstly, get the engine fully warm every time you use it.  Secondly, blank off the EGR to prevent the gases recirculating.  Neither is a full cure but the first will delay the onset of symptoms and the second will prevent it forever at the cost of increased emissions from cold (which may become part of the testing regime at some point) and, in many cases these days, some for of engine warning.

 

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