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Couldn't wait till sat so put it back to how it was. Cleaned the old egr. Started and ran perfectly!!! No smoke no hiccups, perfect.
One thing I did notice was that the spring on the butterfly was in a different position ticking over between the both of them & I think this was the difference but why I do not know.
Also pulling off the egr vacuum pipe when put back to standard made quite a difference to the tick over so looks like mine will have to stay as it is. I can only think that my remap (emaps) may be the reason for this.
Glad there was no lasting problem so will have to leave it as is.
At least the egr got cleaned. . . . Also, the pressure required to open the valve itself is immense. Pushing it with a screwdriver will open it but you won't be able to hold it open for long.
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