How to fix EGR Soot Buildup in a Turbo Diesel

Soot Buildup due to Exhaust Gas Re-circulation (EGR) in Turbo Diesel engines is a big problem. Not only does it reduce engine efficiency, but also reduces power and torque output over time. The worst part is because of the gradual degradation, people often don't realize just how much performance they're missing.

In this video we take a look at some of the common methods used to combat the problem, and their various strengths and weaknesses, from blanking plates and dummy load resistors, to custom tuning.

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[hearliam]

I installed the EGR cable and my economy went through the roof and the power is amazing, my engine is finally awake, for $80 it's brilliant, no faults on the dash, love it, and also get a throttle controller, you won't believe the difference in your car.

[afterburner]

Thanks TheLsdAddicted
The best way to prevent turbo and egr faults is to make sure you rev it and keep it over 2500rpm, this way the turbo engages and runs long enough to spit out almost all over 400k miles, still original egr and turbo, still pulls like a monster for a 116hp engine on an almost 2t vehicle

[moisty]

On my 4jj1 it was a case of a 6k ohm resistor replacing the iat sensor to electronically shutoff the EGR solenoid (doesn't affect air:fuel ratios on my engine as it is determined via the maf and map sensor). Next a blanking plate on the exhaust side of the EGR cooler. Then clamp the coolant hoses on the cooler. Next step is blanking plate on the solenoid side. After that install a catch can or vent to atmosphere. Then finally do a proper intake manifold clean and your car will love you to bits.

[foresterboy]

I have a diesel SH forester and to prevent soot build up is to not use it on short trips but if you do then stay in 2nd or third gear around town to make engine work harder and revs stay higher. Diesel engines as we know are designed to travel huge distances like lorries/trucks do. This is what I was told by a seasoned Subaru mechanic.

[ericrosado]

Brit, I just bought a vw sportswagen dti 2015. And just subscribed to your channel. I'm really enjoying all the information and learning so much on tuning on these smaller diesel engines. Being a heavy duty technician for so many year's this vehicle is my retiement gift to enjoy and play with for year's to come! Cheers...

[kevinoneill]

Yes. I have a large V8 Amarican the F350 6.4 I have been 200cc of 2 stroke mix for every 65 leters of fuel or 17 gallons

[mattoaida]

Did some work on a BMW 335D and the inlet manifold had so much carbon build up, i think the EGR system is so stupid, im glad my friend did the EGR delete but cleaning the intake manifold took a full day. Its a pain cleaning all the carbon build up

[MrIsak]

This guy seriously knows his way around a vehicle engine. I wish my local Garage was as good.

[shammz]

I have a MK5 Golf 2.0 GT TDI! I had the engine management light on and displaying emissions fault! I basically stripped off the EGR valve and throttle body and cleaned them both using white spirit! Reassembled everything and engine management light disappeared!!

[TheLsdaddicted]

The best way to prevent turbo and egr faults is to make sure you rev it and keep it over 2500rpm, this way the turbo engages and runs long enough to spit out almost all over 400k miles, still original egr and turbo, still pulls like a monster for a 116hp engine on an almost 2t vehicle

[paulrodger]

I put an egr blank on my 3.2 4m41 from new . no probs ever .. less than 2 mm build up of soot at 222000 kms when I dismantled to do Tappett adjust and new timing chain guide. I also have been using Penrite hpr 15w 40 engine oil from new changing every 7500 kms
instead of 5 w 30 as recommended....Zero chain guide wear noted .i think the key is thicker oil to decrease oil misting and limit or stop the egr.

[stevewaclo]

install the plug, if you dont mind looking at an MIL lamp. In an emissions testing jurisdiction, a check engine light is an automatic fail.

[FatRakoon]

I bought a SAAB 93 1.9TDI a couple of years ago and in just a few weeks, it went into Limp mode and upon inspection, I saw that there were these weird things hanging out of their holes, and the holes were so badly worn, that they were fairly much rounded off squares and egg shaped instead of circular. I had to replace the inlet manifold and the EGR valve was clogged up to buggery.

Im not a diesel mechanic, Im not any kind of mechanic if I am honest and so I got my mate to sort it out.

The engine light kept coming back every time we clear it ( still does ) and so, as a suggestion, what we did at first was simply blank it off... then he suggested drilling a small hole, so I put an 8mm hole into the blanking plate, then a 10mm and now its got a 12mm hole.

I have, for the last month maybe a bit more, been using the best diesel that I can get locally and that is Shell optimax, and this has done 3 things that have made me decide to never go back to cheaper fuel.

1 - My car is purring like a very contented kitten
2 - It is all of a sudden doing hugely better mileage per gallon
3 - Buying the expensive fual has saved me a small fortune already

In fact, while filling the tank was 17 quid more expensive than the Supermarket crud I was using previously, ( Thats a shocker I admit ), my mileage has shot up and so instead of filling the tank every 5 or 6 days, I am already on day 7 and I still have well over half a tank of fuel left.

The engine warning light is still there but it is early days, plus, I have the 12mm hole and so I am going to just take the plate off completely and see how it goes from there! - I will reset the warning light, it always comes back after only a mile or two, but lets see if it stays off for any longer... Again, Im not expefcting miracles, but I certainly have had them in this last month or so.

Anyway, what I am saying is that to not have your engine fill up with sooty crap, just stop buying cheap supermarket fuel and splash out on good quality fuel... It will be much better in the long run. I used to put Shell in every 4th or 5th tank, just to treat it, but now Im putting nothing but the best in.

I know that many say that it makes no real difference and sure, that may well be true in most cases, but it has albsolutely made a massive difference to my car... It now runs smooth, quiet, cleaner, and is cheaper to run.

Oh and one thing I do admit to, is that the first time, I did put in a bottle of redex Diesel treatment into the tank.

[ronanrogers]

BTW that dongle obviously wouldn’t have a capacitor inside. They usually have resistors to reduce the standard 5 volt signal down to a level that tricks the ECU...but as noted, while it might trick EGR activation it’s also feeding incorrect IAT data which will affect fueling...bad idea, especially on later models.

[louiseoosthuizen]

Good video. This is a common challenge with all turbo diesels.

[Pat.Mustard]

Don’t know about the Tritons but on the pajero the thermistor in the MAF is only used by the EGR. There’s a second temp sensor on the manifold that is used for all the other stuff.

[robertable]

Hi good information, I had a engine management light & restricted performance on my 2.7d xf jaguar, I was fed up with my car I was ready to sale it, my mechanic cleaned the air flow sensor, air filter box & pipes, sprayed Wynns egr valve turbo and inlet manifolds cleaner down the intake, blanked off the egr with blanking plates and finally retuned my ecu which increase my bhp by about 40hp and cleared fault codes. I took my car on the motorway for a clean out, Wow best visit ever to a mechanic my car runs beautifully 70000 miles on the clock, mpg is about 32, take off is smooth but the magic happens once rolling the pull/pick-up is awesome. I would never sale my car now.

[carcranktime]

Mass air flow(for operation related to egr valve)read air flow difference between open and closed egr valve and that is only how ecu monitor egr flow.Air temperature sensor is only for air what is comming in engine..

[llewvirtue]

All good info good luck trying to tune the egr on a vw amarock

[gregwalls]

The cable adds resistance to the air temp for EGR to keep it closed, that's its only function. The MAF has a separate temp sensor for all air fuel mixtures on most modern diesels .