Hi,

First time posting but after plenty of reading around.

My VW T5 2008 with a 1.9tdi engine (BRS) has been feeling underpowered and becomes choked on acceleration, particularly as the you come to the end of accelerating just before you would change gear. Here the engine ‘surges’ with black smoke, presumably as the combustion becomes incomplete.

After testing and checking the following, I have found the EGR seems to be the problem. For now I’ve unplugged it and the engine now runs smooth, but I would like to be sure it’s the EGR before I replace it.

Checked/tested and OK;
-MAF sensor (electrics and sensor ok)
-Vacuum hoses (manually pulled a vacuum and it holds, pressure on main line at 20mmHG)
-turbo hoses not leaking, good seals
-EGR electrics as spec
-N75 solenoid recently replaced (previous ‘moo’ issue
-Air Intake Manifold, Throttle body and EGR valve all cleaned. EGR valve mechanism not obviously damaged and appears to close fully. I don’t have an EGR actuator year tool or VCDS to test the full operation of it.

Engine has only done 70k in its lifetime.

Any advice would be much appreciated so I can rule everything else out before I replace the EGR valve.