Hi all, I am reposting this onto a new thread (originally posted on the EGR Delete Thread), in the attempt to solve my little mystery.

I'm in need of experienced input into likely causes for the following symptoms, but first a timeline of events:

1. Throttle body gears stripped. Replaced the throttle body. FL2 started perfectly. Next day, my wife took it to town, and then car wouldn't start in the supermarket parking lot.

2. Got hold of a diagnostic tool, went to go rescue. Couldn't get it started. Fault code: EGR Valve stuck in open position - so on attempting to start, the intake was flooding with exhaust gas.

3. Made a temporary blanking plate out of a piece of tin, and the engine started. Drove to a mechanic, and we made a permanent blanking plate.

4. Driving home with the permanent blanking plate, I noticed that when coasting to a stop, decelerating from 40km/h down to less than 20km, the vehicle now surged as it hunted for revs - almost fighting against the gearbox to downshift.

5. I was advised to perform an egr delete, and had this carried out. The issue remained unresolved: decelerating to 20km/h induced the revs hunting up and down, and the vehicle lurching/surging as the automatic gearbox tries to downshift. The only way to force the surging to stop, is to press heavily on the brake pedal to slow the vehicle down. This helps to reduce the amount of force on the transmission as the vehicle surges as the revs are hunting while decelerating. Already, this force is beginning to have an impact of the transmission, as I am detecting a sort of slap-back coming from the rear of the vehicle.

6. Took it for another diagnostic, and we are getting error codes PO2E1 - Diesel Intake Flow Control - performance, and P02E9 Diesel intake flow position sensor - Circuit high

Now the questions are, given the number of replies on this thread, could does this surging have something to do with the intake manifold/swirl flaps being clogged causing this surging of revs in-gear while decelerating?

Has the EGR delete & blanking plate somehow messed with with gearbox actuators/shifting settings?

Does anybody have any thoughts/advice/troubleshooting/starting points to consider?

What year is it?

Were the correct TB calibration been carried out after the TB was replaced?
Has the vehicle had anything else changed in the air path? If so was an air path calibration done?


I don't believe it's possible to remove the EGR profile from the ECM, all deletes do is not allow an EGR error to put the light on. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.