EGR / power loss

[CanoeSniffer]

Alfa GT 1.9JTDm

Started suffering a loss of power, 50-100 miles later got an amber EML. Assumed boost leak, power loss not significant and only apparent at ~2000+rpm- coupled with a minor increase in fuel consumption.

Code reader in, expecting MAF fault or similar due to lack of boost- P0401 EGR flow insufficient. Removed EGR hoping to find lots of gunk- not very much. Valve has free movement, gaskets look good, cleaned it as best I could then refitted and still got the code. Struggling to work out what the score is here. Power loss related to EGR code? Any ideas?

[Belle427]

The valve itself could be knackered electrically and not opening correctly.
It’s worth taking the map sensor out and giving it a clean as they can gunk up, I’d give that a try first.

[StescoG66]

The little rod has a tendency to stick - did you separate the black solenoid from the EGR body (it’s only 4 torx screws to remove)?If you didn’t, then do that and check the little activator pin in the middle moves freely. Also when putting back together try to make sure that it is sealed and seated correctly, plus it is worth getting the later issue restrictor plate.

The EGR on that engine is a Pierburg unit and pretty cheap to buy these days. Common to GM too.

[CanoeSniffer]

I did indeed dismantle the EGR via the 4 Torx screws and found nothing amiss. New development, drove the car to work this morning and EGR code has cleared! Still got no bks though.

Methinks I was dealing with two separate issues, and my loss of power is elsewhere. Car has 0 codes, so it’s not something a sensor is able to pick up. Would I have a boost leak with no codes?

[kev b]

Strange as it may seem, the MAF sensor can cause this code.

[StescoG66]

CanoeSniffer said:

I did indeed dismantle the EGR via the 4 Torx screws and found nothing amiss. New development, drove the car to work this morning and EGR code has cleared! Still got no bks though.

Methinks I was dealing with two separate issues, and my loss of power is elsewhere. Car has 0 codes, so it’s not something a sensor is able to pick up. Would I have a boost leak with no codes?

Hmmmm. Check the vacuum actuator pipes too. There may be a split. Can't remember how they are on the GT, but if its like my 159 they are on the RHS of the bonnet slam panel.

[kev b]

No codes running problems are a classic pointer to a faulty MAF