HOW TO CLEAN THE EGR VALVE AND EGR PIPE AND MAP SENSOR AND THROTTLE BODY AND MAF SENSOR.

This How To will cover The Process of cleaning the EGR Valve
And Related Parts Needed if you are having EGR Related Problems
on the 2.0 CDTI Engine But This is also a Recommended Thing to do Every 10 or 20.000 Miles
to Keep the EGR and DPF in Top Condition and keep the Valve from Getting blocked with Soot
this will Save You Costly Replacement parts and problems if the valve gets Blocked and Stuck  
The same Process will Apply to other Diesel Engines
But the Location of the Parts will Differ And the Process of Removing the Parts will be Different.

.........................PARTS NEEDED.......................

1X T27 TORX SOCKET..
1X 10MM SOCKET..
1X 5MM LONG ALLEN KEY OR SOCKET..
1X 4 OR 5 INCH RATCHET EXTENSION..
1X RATCHET..
2 x THROTTLE BODY EGR CLEANER..a few cans.
CAUSTIC SODA..Optional Comes with Risk.
RUBBER GLOVES..
BUCKET..
RAGS..

.........................HOW TO..................................

The First Step is to make sure the engine is cold before working on the car
And then Remove the Battery Negative
Then Remove the Engine Cover and Locate the EGR Valve.
it will be Found at the Back of the Engine Near the Throttle Body.





...Second step...

Remove the EGR Valve,
You will see a Brown Connector Pull the Yellow Tab Back and Pull the Connector Off
You will then see Two Torx T27 Bolts One Bolt at the Top And One Bolt at the Bottom
This is the Awkward One You will Need an Extension on your Ratchet to get this one Out
Also be Careful You will Need to get Right Over the Engine be Aware of the Fuel Pipes on the Injectors
They are Brittle don't break them also try not to Drop Anything in the Engine Bay it is a Nightmare to Get them Out  
Remove the Two Bolts and Pull the EGR Valve out You may See some Coolant come out But There Will Only be a Tiny Bit this is Normal.
There is a Round Metal Gasket that will be Sitting in the Hole for the EGR About 3 Inches Inside
Remove this and Clean it But Do Not Bend it and then Replace it Back into the Hole Before you Refit the EGR
but Really you Should Replace the Gaskets New ones are Best Option.











....THIRD STEP....

Remove the EGR Pipe You will See Three 10mm Bolts At the Top of the Pipe
And Two 5mm Allen Key Bolts at the Bottom of the Pipe
You will Need a Long Allen Key or Extension on your Ratchet to get These out
As There Awkward again to Reach Again Take Care of the Top of the Engine when Reaching over it
when the Bolts are out Pull and Twist the Pipe free and out
There is a Rubber Gasket at the Top of the Pipe Take care this does not fall off.









....Fourth Step....

Clean the EGR Valve and Pipe
You can Clean the EGR Valve and Pipe How You Like You can clean it with EGR Cleaner Spray and do it the correct way
You can Scrape the Carbon Build up out and then Scrub, Spray, Wipe, Soak, Scrub, Spray, and so on
an old Toothbrush Comes in Handy and Leave the EGR Cleaner to Soak for a few Minutes in Between Brushing  
And So on Till The EGR is Clean and This is the Recommended Way To clean the EGR.

Or You can Soak the EGR in a weak Caustic Soda bath with hot water for 5 mins Max checking after the first 2 mins
if it looks Cleaner after 2 mins then Remove it Rinse with Clean Water and Remove the Rest with EGR Cleaner
This will Eat the Carbon much Quicker and will Help if your EGR is Really Clogged up Badly with Hard Carbon
But if Left too Long it can also Eat the Alloy and even Damage the EGR  
You can Submerge the Pipe for Longer but Do Not Get Any of this Stuff on Any Plastic Parts or Connectors on the EGR Valve
Do Not Use With Plastic Pipes this is for Metal Pipes Only,
This is Nasty Stuff if it gets on Skin Please Read and Follow the Instructions on the Box Carefully  
Fill the Bucket with Just Enough to Clean the Metal Parts Only
Do not Knock the EGR Over stand Upright just below the Metal Plate in the Bucket Take Care
And Wear Eye Protection and Rubber Gloves and Cover Skin again Read the Instructions Fully
After the parts have had a Quick Soak as short a Time as Possible Max 5 mins
Wipe the Parts Clean and then Rinse the Metal Valve and Pipe with Clean Water and Wipe and Dry
But Again Keep the Top Plastic Bit of The EGR Clean and DRY when Rinsing
Do Not Refit till Fully Dry Leave Standing for a Good While  
Dispose of waste in the Bucket Responsibly it's Now very Nasty Black Acidic Toxic Waste.
i Actually Recommend the Caustic Soda for the Pipe but again not to Long
But Only a Quick Dip 2 mins for the EGR if you are Having real Trouble Removing the Carbon Build up with the EGR Cleaner
It is more of a Last Resort Method it Has to be Mentioned
As there are Loads out There who Say to use it and this Has been Mentioned and Explained so you know the Risks.
The Same Risks will Apply to Oven Cleaner it Caustic.

Really Try the EGR Cleaner its Just Safer and Kinder to the Alloy on the EGR
And just Safer All Round.    
















Now Take a Rag and Spray it with EGR Cleaner and Wipe the Inside of the Inlet Holes for the EGR and Pipe
on the Engine and get them as Clean as Possible Take Care not to Knock Any Chunks of Carbon into the Intake Holes
Then you can Refit the Pipe and EGR Valve Back into the Car Do Not Over Tighten the Bolts 10nm is Fine
Reconnect the Connector and Push the Yellow Locking Tab Back in Place
and check the Coolant Levels Keep an Eye on it for a Day or Two just Incase you have Any Leaks
But i would Move onto the Throttle Body Cleaning Procedure Before you Refit the EGR and Pipe
This will Make Cleaning Inside the Inlet Manifold Pipe where the EGR Pipe Sits a lot Easier  



....STEP FIVE....



....THROTTLE BODY CLEAN....

..TOOLS...

T30 TORX SOCKET.
10MM SOCKET.
Rachet Plus Extension.
THROTTLE BODY CLEANER.

It is a Real Good Idea to Clean the Throttle Body and Inlet and Out Let Pipes Connected to it
After you have Done the EGR Clean Do this Before you Fit the EGR Pipe Back as this will Help You
Clean Further Inside the Inlet Manifold.
First Remove the 10mm Bolt from the Holding Bracket on the Intake Pipe
and Remove the Two Small Pipes from the Intake and move them out of the way
Then Pull the ECU Out the Way also so you will have Better Access to Get to the Bolts
Remove the 3 T30 Torx Bolts and Pull the Intake Pipe Out









Next Remove The 3, 10mm Bolts from the Throttle Body
Remove the Brown Connector and then Pull the Tab Out Then Pull the Connector off
You can now Remove the Throttle Body and Clean with Throttle Body Cleaner
and Clean out the Inlet and Out Let Pipes also with a rag and cleaner
There is a Rubber Gasket on the Plate Around the inlet pipe Make Sure that has had a Clean also
And Then Refit it as Above in Reverse and then you can Refit the EGR as well.










 

....Step SIX....

MAP Manifold Pressure Sensor Clean.

Tools

T30 Torx Socket
10mm Socket
Ratchet Extension
EGR Cleaner  

The First job is to Locate the MAP sensor Position on the Inlet Manifold at the Back of the Engine
This is a Very Tight Space to Work so a Few Things have to be Moved out the Way to get to the Bolt on the Boost Sensor



Remove the Black and Yellow Connector on the MAP Sensor that needs to be Removed out the way
Just Pull the Yellow Tab back and Pull the Connector off
You will see a 10mm Nut Remove this and Move this Sensor out of the way
There is a Pipe that would be Best Removed but Leave it Alone as it is not Easy at all to get that off and you Risk of Splitting the Pipe.









Next just Near to the Torx Bolt on the MAP Sensor you will See a 10mm Bolt on a Black Plastic Bracket
Remove this Bolt this will Help you Move the Pipe Slightly out off the way to get Access to the Blot on the Boost Sensor
After that Remove the Connector on the MAP Sensor
Again this is a Very Tight space to work in Dont Drop the Bolt.





Next Remove the t30 torx Bolt Holding the MAP Sensor this is still a Very Tight thing to get out
so be Careful Removing it then Push the Tab Down at the Bottom Holding the MAP Sensor and Remove the MAP Sensor









Next Clean the MAP Sensor with EGR Cleaner to Remove the Carbon Build up and Scrub it with an old Toothbrush
Keep the Connector Plug Part free from Cleaner and as Dry as Possible
After you have Cleaned the MAP Sensor Refit it to the Car as above in Reverse Order
Just Take Care Getting the Bolts Back in as it is Tricky so Take your Time.







....STEP SEVEN, MAF CLEAN, Mass Air Flow....



..TOOLS..

7MM socket.
MAF Cleaner.

You may as well Check the MAF, or the Mass Air Flow Meter is Also Clean
and Check the Condition of Your Air Filter while you are There
Unplug the Connector Pull the Yellow Tab Back and Pull off the Connector
Other Models will Have Two Screws just Undo them and it will Just Pull Out  
2.0 CDTI just undo the Two 7mm Bolts on the Clamps and Pull the MAF Casing Out
Spray with MAF Cleaner and Allow to Dry do not Rub the Sensor with a Rag
Just Leave it to Dry and then Refit it back Together.









....Next and Last Step......Fuel Additives.........



Now you have Done all That Start the Engine and Let the Car Idle Till the Engine is Warm
Fill the Car up with a Good Quality Fuel like Shell V Max use a Full Tank of Diesel
and add a Good Quality Diesel Fuel Injector Fuel Cleaner Treatment Additive and add to the Full tank
This will Help Clean the Injectors and Fuel Sytem out.
And go on a Long Run Altering the Driving Conditions and Rev Range
Have Fun your Car Should be Feeling Better for Your Hard Work.

Also you may want to Think about Changing the Fuel Filter also
and Adding a Good Quality DPF Treatment on your Next Fill up to Further Clean Things up.

https://www.vxoc.org.uk/forum/Thread-How-to-change-fuel-filter-diesel-cars

http://www.ebay.co.uk/itm/141809892366?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

You may want to think twice before using supermarket cheap diesel in the future
Yes its Cheap but its Your Engine and the Cleaning Additives they use in their Premium Fuels do Help keep things Cleaner
and Every 3 Months add a Good Quality Fuel and Injector Cleaner to the System

if you are Still having Problems you may need to Run the Engine and put EGR Cleaner through the System
Holding the Revs at 1500 rpm and altering to 2.500 rpm and Squirting the EGR Cleaner in Quick Blasts till the can has Gone
this may Trigger an Engine Management Light this may Clear on it own or you may have to get it Reset
Seek Advice before Doing this or ask a Professional there are Products out there for the Job.
you may have other Problems like cracked intercooler pipes, turbo problems or blocked breather pipes, DPF issues, Swirl flap issues, etc  
if problems Persist you should Seek Professional Advice.
this How to is More for Maintenance and Prevention of Problems but it will Cure Most.

Always disconnect the battery before unplugging any electrical connectors to avoid error messages.

....EGR TECH INFO...

http://www.vxoc.org.uk/forum/Thread-Servicing-the-egr-valve?pid=17518#pid17518

AS WITH ALL MECHANICAL HOW TOO,S. 
you do this at your own risk if you follow the how to correctly 
there should be no problems thank you.