2.0HDI EGR vacuum system fault from manufacturer

[Bluepug504]

2003 Citroen Berlingo Desire 2.0HDI @131K miles
For information:
My car was down on power and torque (approx. 20%) and after reading many internet threads, the main suspects to check were the MAF, EGR system and turbo system.
After cleaning the MAF, (something I had never thought to do in 13 years of ownership) a noticeable improvement in power and response was noted.  However, I thought I would still inspect the EGR system and try and prove it was functioning correctly. When checking the integrity of the vacuum hoses it became apparent that there was no vacuum to the control solenoid and therefore non to the EGR Valve. The vacuum hose uses a plastic splitter to distribute the vacuum to the solenoid and also to the brake servo.  This plastic splitter was blocked with plastic ie it was either moulded incorrectly or the port never drilled out.  I opened up the connection with an appropriate sized drill bit and vacuum was achieved all the way to the EGR valve.
What it means though is that the EGR system on my vehicle has never been in operation and I have to presume the valve has never opened in all that time. No doubt, now that vacuum is restored to the valve I will suffer endless EGR issues.

If I was a conspiracy theorist, I may conclude that Citroen fitted the equipment to comply with the emissions legislation of the day but fitted a small defeat device so that it was never in operation and hence never failed!!! Mmmmmm.

Anyway, something to check if you have no vacuum to your EGR solenoid.

[jj9]

I would block it back up if I were you.



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[cancunia]

After that many miles, probably best to do as jj9 suggests and put things back the way they were. Your ECU must be mapped to not expect a drop in air volume with the EGR open, so fixing the vacuum & EGR could cause too little air in the MAF.

My 2.0 certainly complains either with too much, or too little EGR.

[FredFlintstone]

2003 Citroen Berlingo Desire 2.0HDI @131K miles
For information:
My car was down on power and torque (approx. 20%) and after reading many internet threads, the main suspects to check were the MAF, EGR system and turbo system.
After cleaning the MAF, (something I had never thought to do in 13 years of ownership) a noticeable improvement in power and response was noted.  However, I thought I would still inspect the EGR system and try and prove it was functioning correctly. When checking the integrity of the vacuum hoses it became apparent that there was no vacuum to the control solenoid and therefore non to the EGR Valve. The vacuum hose uses a plastic splitter to distribute the vacuum to the solenoid and also to the brake servo.  This plastic splitter was blocked with plastic ie it was either moulded incorrectly or the port never drilled out.  I opened up the connection with an appropriate sized drill bit and vacuum was achieved all the way to the EGR valve.
What it means though is that the EGR system on my vehicle has never been in operation and I have to presume the valve has never opened in all that time. No doubt, now that vacuum is restored to the valve I will suffer endless EGR issues.

If I was a conspiracy theorist, I may conclude that Citroen fitted the equipment to comply with the emissions legislation of the day but fitted a small defeat device so that it was never in operation and hence never failed!!! Mmmmmm.

Anyway, something to check if you have no vacuum to your EGR solenoid.

I've been having EGR issues regularly for a number of years and my latest attempt to get it sorted was this morning when I had the whole EGR system professionally cleaned and was advised at the end of the process that there was virtually no vacuum evident from the Vacuum pump. 
Before I spend even more money trying to get this sorted out, Bluepug504, how has your EGR issue been since you drilled out the plastic splitter? I've not checked mine yet but I know where it is. The cleaning operative said he had taken the hose off the vacuum pump and that the pump itself was producing next to no vacuum pressure.
Mine is a 53 plate Berlingo Forte 2.0 HDi.

[cancunia]

As mentioned in the OP, the vacuum pump also provides vacuum for the brakes. Do your brakes work ok? I've never taken the pump apart but seem to remember something about it having a filter, maybe that's blocked?

[FredFlintstone]

As mentioned in the OP, the vacuum pump also provides vacuum for the brakes. Do your brakes work ok? I've never taken the pump apart but seem to remember something about it having a filter, maybe that's blocked?

Thanks cancunia - the brakes do work, but the EGR cleaning techie thought there wasn't a lot of 'servo assistance' on them but it maybe what both he or I are used to.
I could look at taking the pump apart and seeing if it has a filter that needs cleaning as a next step. I'll have to look at how easy it is to get off and then taken apart!

[jj9]

. . . the brakes do work, but the EGR cleaning techie thought there wasn't a lot of 'servo assistance' on them but it maybe what both he or I are used to.
I could look at taking the pump apart and seeing if it has a filter that needs cleaning as a next step. I'll have to look at how easy it is to get off and then taken apart!

Test the operation of the brake servo to see if it's getting enough vacuum, test procedure in the link below.... 


https://pagid.com/wp-content/uploads/201...cedure.pdf


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