EGR Hell - Help required

[gulab100]

Hi Folks,

I have a 2007 Corolla Verso with the T180 lump that I am having issues with.

All was well with only the odd limp mode over the last 2 years. Typically this was *rap in the EGR. Cleaned and off we went. 

I was giving it a blast before MOT and noted that the power was really slow to come in. It used to be like *hit off the proverbial shovel with power arriving around 1000rpm. Months later and it's worse than ever. Power arriving at more like 3000rpm if it gets there, limp mode on a daily basis and when the turbo does spin up, it's like night time behind the car. So I set about sorting it out.

So far we have: New fuel filter, new air filter , new EGR valve, new MAP filter, inlet manifold removed and cleaned, new suction control valve. All faults removed. TRC and VSC with engine light return after a few mins. Fault cods are EGR flow. Occasionally an erratic MAF flow fault. That's been cleaned with the correct cleaner.

Car is mainly driven slow in the local Devon lanes, but it's always had a weekly blast. I missed an oil change last year, but till then it was always done with the correct oil. Always Shell fuel.

After all the above work and time, I'm at a loss. Any ideas anyone?

Has anyone seen an EGR cooler choke up? It's about the last thing on the list. It's also the one that I cannot really get to. Is there access to the fuel tank sender in the car?

Any help is much appreciated. It's just about un-driveable and It'll have to go if I cannot sort it. Shame as it's a great car.

Ruperto