Citroen is racing again! Or is it?

The Citroen Xsara Picasso was a very successful model, it was very popular. Its shape was progressive and its technical solutions were good. But what about a 2007 model (launched in 2008) with 304.000 km and the famous 1,6 HDI engine?

A friend of mine called me to say that his wife's Citroen had given up the fight. He was immediately told that it was probably a cylinder head problem and that the costs would be hundreds of thousands. He asked if I would arrange the repair, as I know several reliable, very professional car mechanics.

He brought it to me, I asked around, and then I finally went to my mechanic friend Józsi, asked for his laptop, and read the error codes. And I had to realize that this was a true car. After all, the Bible says that the true has many problems. Well, this one has many problems. But none of them could have caused the problem described, which was the following:

Their bricklayer was driving a Citroen that had seen better days, with about 400 kg of building materials in it. The temperature was around 36-38 degrees and the blessing of the Budapest traffic jam came on. Suddenly, a yellow light probably flashed on the dashboard and the car wouldn't go any further. My friend went over, the little Citroen started up, drove a little, stopped, started up, drove a little. And so, dividing their strength, a little old, like an ancient electric car that needed charging every 10 km, they drove home.

So, after reading two error codes, I tried looking at the real-time data with the engine running – I thought – what if it detects less temperature and the fan doesn’t turn on, but there was no problem with the temperature. What I have to say is that I could always ask my two car mechanic friends, Józsi and Péter, who work nearby, and if needed, they also lent me tools and a diagnostic laptop.

So I was quite at a loss. Then I had to go to Százhalombatta, I thought I would go with the Citroen, my friend also told me to test it, and there was much more diesel in it than there was gasoline in my little BMW. What is also important is that the little artistic Picasso worked very well, there was no sign of any error. It started nicely even when cold, when I accelerated, the small turbo pressure came nicely and the 90 horsepower made the approx. 1300 kg chassis fly. But let's not forget about the consumption of around 5 liters!

So off to Batta. Up the highway, air conditioning on (and even cruise control!), 3rd, 4th, 5th and 120 km/h! We're speeding! And a yellow light, a nice big "ENGINE FAULT" sign! The engine stalls, I quickly put it in neutral and rolled towards the exit.

Two thoughts came to my mind at once:

1. But okay, there's the error!
2. Damn it, I'm late!

As previously described, I drove home at a fairly measured pace, while calling to say I was late. I got into the BMW and took care of my business. Then I went home, into the Citroen and over to Józsi's. I plugged in the laptop and read the error codes. A new code, P0409, appeared.

 Come on, our good friend Google – I don't like its camera car – but the search engine is always a great help!

And here it became clear that the problem was with the EGR valve. The essence of the EGR valve (exhaust gas recirculation): The EGR valve provides the connection between the exhaust pipe and the intake and regulates the amount of recirculated exhaust gas. A detailed description can be found on Wikipedia.

So there was a reason for the error. There was some advice to have the EGR valve checked, it was just the problem anyway. But I also received information from a third mechanic, locksmith and paint shop friend of mine that the operation of the EGR valve will be an exam requirement next year, and checking it out is not a cheap pastime.

So this is not a track. A new valve is 65.000 HUF, and that's not the real thing either. I left with version C, the cleaning. After all, it's a good little installation, I just got around to it, it promised to be a good adventure. I found an extremely good English-language video about this operation with the same engine and I bravely started it. Fortunately, I didn't watch the video in advance, otherwise I don't think I would have started it.

The assembly (Sorry if it's too detailed, feel free to scroll through.)

I followed the video step by step, which I link here . With one easy move, I removed the plastic engine cover and the two large plastic air ducts. Sorry for not using the exact names, this is not my profession, just my hobby.

The one on the right was just snapped in, while the one on the left was clamped on top and bottom. To get the fuel filter out, I had to pull the brake fluid reservoir out of the mounting rail and set it aside, even pulling off the small tab on it.

Following the video, I also removed the small shield, it was held in place by three screws. A very clever solution from YouTuber “ more molecules ” was to cover the open openings, such as the turbo, with simple kitchen foil, a method I adopted as well.

So I pulled the electrical connector and fuel lines off the filter, then tried to pull the little tab on the left side to pull it out, but it wouldn't budge. I tried to push it, force it, but it just held its position. Finally, it started to wiggle left and right and I was able to lift it out.

I finally saw the much-coveted EGR valve. But I couldn't fit it. The air filter housing had to be lifted out somehow, but it just wouldn't fit. This didn't match the video, I think more molecules installed a Berlingo, there's a lot more space there on the side facing the firewall. As a test, I removed the front part of the air filter housing, which also has a sensor. After that, I was able to move the part out and had quite good access to the EGR valve. With the help of a mirror, I checked what kind of clamp it was holding on to from the left. Unfortunately, it was the factory type that could be seen in the video. And I didn't have the necessary special pliers for this, and neither did Péter. However, they had those strange flat pliers with which I had a chance to remove the factory clamp. After that, I went to a car shop and bought the screw-on, easier-to-use version to replace this clamp.

Next came the removal of the clamp, which was easy with the pliers Peter gave me. Then I unscrewed the two screws and BOOM! I had the EGR valve in my hands.

I sprayed both passages with WD40, and a lot of dirt came out.

And unfortunately there was a fatality who gave his life to clean the EGR valve. And he was an old toothbrush. God rest his soul. He will not be resurrected, we have a chance.

So, after watching the video, I removed the top of the part and cleaned it too. It was encouraging that after I removed the EGR valve, its little latch didn't move, but after cleaning it, it wiggled nicely.

So the EGR valve is clean! Now all you have to do is put it back together. I won't describe it in such detail. If you read the part above backwards, you'll see the process. I'm proud of the fact that I didn't use the video for the assembly. I was a little worried about the handful of parts left, but if the car is lighter, it will run better! Of course, I'm just kidding. There's nothing left.

What was also a plus was that there was a rubber ring in the middle of the air pipe and in the EGR valve. The one in the EGR valve was stretched, and the one on the air pipe was completely brittle, it looked like the car was beating oil there. I went to a nearby famous car shop to buy these two parts. The sales guy was very nice, but even after an exhaustive search, we couldn't find such a part separately. There was only one solution: an air pipe for 36.000 HUF and an EGR valve for 65.000 HUF. I was a little disappointed. I didn't have that much money with me. I said I'd try it at the bearing shop. They were also very nice there, the salesman measured both sealing rings, and then brought the new ones. I bought two of both just to be safe. And that's how I ended up cheaper. I paid 1200 HUF in total.

So I put the Citroen back together. I just had to start it. Will it start? Will it stall again at 120?

No. It started very well and even handled highway speeds with the air conditioning on, so I'm happy! Unfortunately, the check engine light is on because there are still error codes, but it doesn't shut off anymore.