2011 Burstner t660 egr issue??!! Help!

[Cochyn]

Hi , posting as really fed up at the moment! Our 2011 nexxo t660 amber engine light came on about 7 weeks ago now and had no power. Okish on the flat but any hills I needed to change down to 2nd! Took it to our local garage who did diagnostics and said it pointed to EGR issue. I had a warranty provided when i bought it so thought great go ahead. They checked the EGR and it was clean so wasn’t causing the issue apparently. The warranty wouldn’t cover this as wasn’t faulty. £250 down. The garage then said it would be best if I took it to a Fiat dealer who have a specific diagnostic machine. Took it to one 45 minutes away at £110 an hour . Couple of weeks later said they needed to take manifold off and they found it caked with carbon-see pics. Said they cleaned it and took it gor a test drive and sorted -£700. Also told me as van was 2011 the Fiat diagnostic machine didn’t work on ours so used snap on which I think my original garage use but only charge half the price per hour!
Picked it up Thursday after work as going away the weekend and no change-still no power on hills etc. had to take it home as going away the weekend
Subsequently took it back after the weekend and made the error of telling them no rush as going on a 10day cruise! Came back-hadn’t looked at it. Eventually did yesterday and now they say they think it’s a faulty EGR valve! Fiat one £800 non fiat £400.
Phoned warranty company again -told to email fella who i had dealt with previously. Had email back saying they had found one on europarts for
£24.99! Phoned garage and they said wasn’t a full egr valve but willing to try it. I don’t have much idea with vehicles so any advice is greatly appreciated. Think I found a full egr valve for our van for £280 but not certain? Broken Link Removed. I’m thinking of going for the £280 but not sure?
Any other owners had similar issues and could shed some light please? Many thanks. Daf

 

[newmoontime1313]

Had the same thing ok on the flat when you get to speed any hill massive lose off power
Truned out to be the turbo actuater on top off the turbo.Very small pin holds the arm in place
and they break away.Hope you get it sorted soon

 

[Cochyn]

Worth mentioning it to the garage. Thanks very much

 

[Cochyn]

Was it a big job?

 

[Cochyn]

Had the same thing ok on the flat when you get to speed any hill massive lose off power
Truned out to be the turbo actuater on top off the turbo.Very small pin holds the arm in place
and they break away.Hope you get it sorted soon

Was it a big job to do?

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[newmoontime1313]

No had a mate put a spot weld on it no problem since just drove all across France/Spain/Portugal
Have a look at the Fiat forum they are a hive of info and pics of the job.He put the weld on two years ago

 

[Cochyn]

No had a mate put a spot weld on it no problem since just drove all across France/Spain/Portugal
Have a look at the Fiat forum they are a hive of info and pics of the job.He put the weld on two years ago

Many thanks

 

[Guigsy]

The 2.3 engine used to commonly fail at the throttle body. The throttle body the the point the EGR gases re-enter the intake. If the engine has been running, when you turn it off, about 5 seconds later, there should be a sharp snap from under the bonnet as the actuator closes the butterfly in the throttle body. Lack of noise or sounds like a straining servo could indicate the throttle body is dodgy.

 

[jockaneezer]

Can't believe that the egr was clean if that's the condition of the inlet manifold ?
The throttle body is a good shout, but I think your turbo might be gummed up too, can the first garage take it for a run and post some live data for the turbo boost, throttle position, etc ?
I stripped out the egr on my car recently, the actual egr flap was working fine, it was the water cooled section that was choked and had brought on the engine light.
Before.

After.

 

[Cochyn]

Can't believe that the egr was clean if that's the condition of the inlet manifold ?
The throttle body is a good shout, but I think your turbo might be gummed up too, can the first garage take it for a run and post some live data for the turbo boost, throttle position, etc ?
I stripped out the egr on my car recently, the actual egr flap was working fine, it was the water cooled section that was choked and had brought on the engine light.
Before.
View attachment 828468
After.
View attachment 828467

Will ask them. Thanks

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[Cochyn]

Can't believe that the egr was clean if that's the condition of the inlet manifold ?
The throttle body is a good shout, but I think your turbo might be gummed up too, can the first garage take it for a run and post some live data for the turbo boost, throttle position, etc ?
I stripped out the egr on my car recently, the actual egr flap was working fine, it was the water cooled section that was choked and had brought on the engine light.
Before.
View attachment 828468
After.
View attachment 828467

Would that affect its performance-no power on hills/acceleration etc?

 

[jockaneezer]

Cochyn, we were down on power, but not into limp mode fortunately, but one of the most noticeable things (apart from general poor acceleration) was the car used to hesitate, as if you'd just lifted your foot of the gas for a nano second, especially noticeable when driving steadily around the 40/60 mph mark ?

 

[Cochyn]

Cochyn, we were down on power, but not into limp mode fortunately, but one of the most noticeable things (apart from general poor acceleration) was the car used to hesitate, as if you'd just lifted your foot of the gas for a nano second, especially noticeable when driving steadily around the 40/60 mph mark ?

Ours is shocking on hills now-down to 2nd-was yours similar?

 

[Landy Andy]

Have they physically checked your EGR is closing

 

[Cochyn]

Have they physically checked your EGR is closing

Not sure about that

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[jockaneezer]

Ours is shocking on hills now-down to 2nd-was yours similar?

Ours wasn't too bad on hills, never had to drop down a gear. It's a Volvo V40 with the 2 litre diesel, so not that heavy a vehicle for the 2 litre motor to cope with ?

 

[Landy Andy]

The soot build up in your inlet manifold indicates that your EGR valve is stuck open to me as that is the only way that soot can get into the intake system. You need to physically know if it shutting. The EGR not shutting will cause turbo not to operate properly and can cause the turbo to fail, which it may have done with yours if so down on power, or could be on its way. It could be a failed vacuum solenoid causing the EGR issue. The vac solenoid it the black thing that is under the bracket that is bottom of windscreen middle that rain water runs across. This operates the EGR valve.

 

[Cochyn]

The soot build up in your inlet manifold indicates that your EGR valve is stuck open to me as that is the only way that soot can get into the intake system. You need to physically know if it shutting. The EGR not shutting will cause turbo not to operate properly and can cause the turbo to fail, which it may have done with yours if so down on power, or could be on its way. It could be a failed vacuum solenoid causing the EGR issue. The vac solenoid it the black thing that is under the bracket that is bottom of windscreen middle that rain water runs across. This operates the EGR valve.

Just been up to the van and engine had water on it due to the water getting in between the plastic cover in the middle-shocking design . Thanks for the advice will give it a go once EGR valve changed as warranty have said they will cover the cost of that

 

[Cochyn]

Ours is shocking on hills now-down to 2nd-was yours similar?

Yep on a big hill. Down to third and struggling on one that would probably have flown up in fifth