S/V40 1.9D Shut-off throttle & EGR valve

[Baffler]

In relation to Baffler's post, he mentions removing the three studs, is that all there is to it?

It's been a few years but, yes, I believe I just removed the three screws and the valve came away from the manifold. As it wasn't very dirty I just cleaned it with the vacuum line still attached, popped in the new gasket and reattached it to the manifold. Be careful not to over torque the screws (only 9 Nm) on replacement as the plastic housing of the valve can become quite brittle over time. A little drop of low strength thread-lock on the screw threads will keep them in place without having to over torque.

Also, I started removing my EGR valve and half came off and the rest is stuck in the manifold (!!). It is completely caked with sludge and soot as is is the manifold. Does anyone have an idea of how I can remove the valve and clean the manifold. (I have already dragged a lot of the gunk out of the manifold with a bent hacksaw blade)

Along with penetrating fluid you can use a pipe wrench (Stillson) to gain enough purchase on the triangular flange of the inner most part of the EGR valve. It will eventually come loose.

Ideally, to properly clean the manifold, it would need to be removed but that would mean the turbo needs to be removed to create enough space to maneuver the manifold.

To remove the heavier deposits I have successfully cleaned mine by using a collection of improvised tools. A long tea spoon/ice cream spoon with the head bent to 90° and an old vacuum cleaner is very helpful to catch any large deposits from dropping into the manifold. Copious amounts of cloths, rags, paper towel and brake cleaner...oh and nitrile gloves a must...it's a dirty task.

[HalV40]

Don't know if it will help anyone with EGR issues (poor idle, hesitation when accelerating) but I simply unplugged mine on my 2001 1.9d and I've had no issues at all since, no error lights and passed MOT no problem with the emissions.
Happy days.