EGR horror!

My Cruiser was like that I pulled the intercooler pipes off and cleaned them all. Did it again.

I went to Toyota and asked them about it and was told Perfectly normal so didnt worry about it any more.

EGR systems were introduced to assist in the reduction of nitrogen oxide gas in the exhaust. Basically inert gasses from the exhaust are introduced into the combustion cycle to reduce temperatures that allow the formation of this bye product. Unfortunately this also reduces the performance of the vehicle to a degree.
I believe that like tampering with any other of the emission controls of an engine, this, strictly speaking, is illegal. Probably why a fault is recorded on the ECU of many vehicles.

I have read that research into other more efficient emission reduction strategies are making the use of EGR less favourable.

Cheers
Pop

So you didnt need the EGR? Michael

It's becoming pretty common these days for people to block it off and put a catch can on and plum it back into the sump or just put a tap on it so it can be drained occasionally it may be illegal but it will save your motor.

EGR is only open when the engine is under light load say cruising at 100Kmh.
Under any heavier load it is closed by the ECU.
While the EGR valve can be a restriction in some engines, it is really doubtful that the EGR valve will cause a drop in efficiency of the engine under full load conditions, as it is closed.
In my case I took off my inlet manifold on my Land Rover TD5 at about 140Kk and there was a lot of coke on the valve itself and that black crap in the manifold.

However a clean with a scraper and Gerni saw most of the coke transferred to my face and hair in no time.

The main thing to watch with aTD5 anyway is that the MAP sensor does not become gunged up. I believe that this is also a problem with VMs in Jeeps, 3.0 Patrols , and Mitsubishi Pajeros and probably others.. My wife's cousin had his Mitsu go into limp mode while going up Cunningham's gap towing a van. Mitsubishi replaced the manifold with a relocated MAP AFAIK .

I have left mine in place and just monitor the MAP , and using full synthetic diesel oil it has not become coked again in 35KK. They EGR tends to coke up cars that are not run hard eg stop start around the city.
I have a delete kit but I am loath to fit it, because of possible fault lights and the fact that in a Land Rover the bolts holding the EGR plate to the exhaust manifold are known to shear off when being undone, which would be sure to happen to me.
And I don't really think it affects performance one bit.
Regards Philip A

Day one with blank plate, no notice in performance but I didn't really expect anything. I've noticed on idle it sounds better and has a bit less vibrations coming through into the cabin. Also acceleration off idle seems smoother up to boost although no notice in boost coming on earlier. As for fuel have not tested yet

Just fitted SPV mod. This was on a 2014 Pajero. Plug in 30 second job.

This module (variable resistor) works by telling the sensor in the EGR that the motor is cold which ensures the butterfly in the EGR stays closed.

By closing the EGR the engine will run hotter and certainly cleaner with no recycled gases. Fuel consumption should be slightly better.

Provent 200 fitted as well. The filling of the manifold with dirty black coke is well known on some diesel motors. Mitsubishi have even replaced some under warranty. Mine is only a new car but I believe in prevention rather than cure. The Pajero Club of Vic is an excellent forum on this subject of EGR.

Cheers

The gunk you describe is pretty standard for EGR fitted diesels - certainly my RRS diesel inlet manifold was the same until I blanked it. My sludge was about 1cm thick after only 60,000km. The main issue for my engine (and I guess the same other CRDs) is that it can cover the Manifold Air Pressure sensor and cause issues bit this is a two minute clean.

In general terms, the egrs are open on trailing throttle feeding in exhaust gases back into the low power combustion process to reduce emissions. There is unburnt fuel in this gas and other "slush" and it is this that accumulates in the inlet system - any that gets into the engine is burnt off.

On full or power throttle the EGRs are closed and the engine burns clean air from the air filter.

That is a very general description only and it is far more complex than that.