JAGUAR X TYPE 2004 1.G EGR Cleaning Manual

X-type Jaguar
EGR Valve


These notes are intended as a DIY guide to removal, dismantling & cleaning a Euro 4 EGR
valve as fitted to Jaguar x-type 07 model 2.2D engine. It is offered as a record of my
experience and as such I cannot accept responsibility for anything YOU do as a result of reading
it!!
EGR stands for exhaust gas recirculation - the EGR valve is the main emissions control component in the
exhaust gas recirculation system.
The valve is located on the intake manifold, and opens a small passageway between the exhaust and
intake manifold to allow a metered amount of exhaust to flow back into the engine. This reduces
combustion temperatures and helps control the formation of oxides of nitrogen. The EGR valve is
opened by the application of vacuum to its control diaphragm. Some also require a certain amount of
exhaust back pressure before they'll open.
On newer vehicles, the valve is electronic and uses one or more solenoids or a small stepper motor
(which is the case in this example).
The valve should remain closed while the engine is cold and at idle. It should only open once the engine
has warmed up and is running at part-throttle. If the valve sticks shut (or is disconnected), NOX
emissions will soar. If it sticks in the open position or fails to close all the way, it acts like a vacuum leak
resulting in a rough idle, hesitation and possible stalling.
Electrical connector
Motor housing
Manifold Outlet
Exhaust Inlet
2 x Retaining Nuts
Hose worm clip
2 x Bolts Intercooler Hose
The motor gear is held in place by 5 spring clips
which can be gently opened with a screwdriver
allowing the unit to be split as shown.
Do it over a cloth as the gearing may slip off when
you separate them!
You will see a large flat spring like a clock - use the
gear wheel with the prongs to turn it to check that
the valve is moving freely.

X-type Jaguar
Looking down the main pipe you will see an amount of carbon deposit which may or may not
be oily – it will certainly be VERY dirty stuff so take precautions to prevent damage to you,
your clothes or your car.


Before
Before
Before
Before
After
After
Gently scrape excess carbon and gunk off with a blunt knife, I used a small flat screwdriver to
prod around the valve housing which was particularly badly clogged. An old toothbrush and
some white spirit got rid of the greasy residue, dry off with paper kitchen towel.
Although now clean the surfaces were blackened so I used some very fine steel wool to get rid
of the surface patina and leave a smooth shiny surface which will hopefully aid the flow of
gases in future.
A quick wipe over, test the valve was still clean and free to do its job by winding the spring as
before and then re-assemble.
Once the gears have been aligned, the retaining cover just needed coaxing back on and then
it’s a simple re-fit - 2 x bolts, 2 x nuts and the hose clips. Its tight in there so watch your
knuckles!!

X-type Jaguar
EGR Intercooler Hose
Is located on the driver’s side at the front of the engine near to the radiator, this rubber hose
connects the EGR valve with the intercooler and is held in place at either end by a threaded
Jubillee clip. This hose is a notorious weak spot on the X-type, as it often splits causing engine
management and usability problems. (If it does split you will hear it make a loud sucking noise
when the engine is running).
The hose is made of 5mm thick reinforced rubber and is similar in appearance to other hoses
typically found as part of a vehicle’s engine cooling system, although in this case the hose only
has gases (not liquids) passing through it.
Outer Dimensions:
Length 280mm


Diameter 60mm Thickness 5mm
There are two offset bends in the pipe:
Inner Dimensions:
Diameter 55mm Thickness 5mm