T27 Diesel EGR Cleaning- Cautionary tale

[Pete Taylor]

Recently bought privately 09 Avensis 2.2 D4D. The usual check parking brake and VSC message came on after 10 miles. Removed egr valve, found to be reasonably clean but cleaned it anyway and reassembled. Warning on again after 30 miles. Removed egr again and this time the "swan neck" connector to the intake manifold. The port into the inlet manifold was completely blocked with carbon. removed carbon and cleared port, reassembled and all is now well so far. The problem is the port cannot be seen unless the swan neck casting is removed (2 nuts, 1 bolt) and it may appear the way into the inlet manifold is clear. Hope this might help someone in the future....

[saxo265]

Hi Peter, looks like I may have the same problem, did you have the flashing/on brake lights (when car locked) as I have? Just posted my problem. Is yours a D-CAT? Any pics of swan neck as I have never done this job before, thanks, Nick

[Pete Taylor]

Hi Nick, no it isn't a D Cat fortunately, and didn't notice flashing brake lights I'm afraid. Can't take pic of swan neck as the car is away with my daughter, but it is the casting the EGR valve is bolted to, which has a round hole at the egr valve end and transitions through 90 degs. to a rectangular hole in the intake manifold. It is fixed to the intake manifold via 2 studs and a bolt. 

Hope that helps.

[Pete Taylor]

PS It seems to me a blocked egr valve gives off all sorts of spurious fault messages, lord knows why, and what has the parking brake etc got to do with exhaust emissions for crying out loud. Just read your post. i have bought a fairly cheap (£25 ish) OBD checker, (Streetwize from ToolStation) and that told me the problem was egr related. Worth getting one to save yourself the £50 or so cost of a check by a garage. And you can cancel the fault with it as well!
Pete 

[saxo265]

Many thanks Peter, will check it soon as.