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I fixed it this way. The EGR valve houses weak PLASTIC gears driven by a
stepper motor with a METAL gear! The intermediate plastic gear had lost a couple of teeth so
was not being driven anymore. As the maximum angle the gear moved was only 90
degrees, I just removed the gear and rotated it so that the sheared teeth are
out of the range of movement. [Some may have to have the fault reset, mine didn't] This can all
be done while the EGR valve is still in situ, just open the top cover [note! torx screws] to reveal
the gears and do not loose the spacer from the top of the middle gear.
 
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