Hi guys, thanks for taking the time to reply, I haven't had any spare time to try cleaning it today and customer putting me under pressure, I couldn't guarantee to him that cleaning would work and cut off point to order new unit for tomorrow was 3pm, he decided to pay for new part!. I haven't looked at egr but there weren't any codes for position fault. Is it possible to be stuck open slightly and not generate a code?. I don't think any warranty due to high mileage. I will have a go at pressure washing old unit and see how it goes for future reference. Thanks Brian