Puma EGR issue?

[Lagerfan]

Hello folks, so lately I've noticed that the puma has been getting a little thirstier than usual, it's a 2.2 MY13 90 no remap but decat'ed. I took some steps to rule out anything obvious: cleaning out the airbox + air filter, cleaning air sensors, swapping to a different servo in case of dodgy fuel etc. with no change. But today on the drive back from Ballarat I paid close attention to the Ultragauge and noticed there's a pattern.... When the EGR flow shows 0% the EGR error is always -100% and the instantaneous fuel usage is very high, like 14-15l/100km under bugger all load doing 100kph on the flat. When the EGR flow is 30-40% the EGR error is some small fraction and the fuel usage is in single digits around 9-10l/100km. This seems completely the wrong way around from my limited understanding of the EGR. Is this telling me the EGR is cactus or at least needs a clean or something like that?

The EGR clean cycle sounds as healthy as it always did over the 10 years we've owned it and there is no check engine light on the dash. The Ultragauge "trouble codes" are empty - not that I've ever seen them show anything - but I don't have a code reader ... topic for another thread but the Gap Tool seems to get the thumbs up around here.

Thanks in advance for any advice

[Tikka7mm08]

Agree that seems very thirsty for open road. May be a good excuse to delete the EGR?? We did our D4 and the saving is a liter or slightly more per 100km.

[Lagerfan]

Yes been putting off getting a BAS remap for a while but maybe time I bit the bullet. Even still I want to know the EGR is working properly and not stuck in some weird state, a remap asking a stuck or clogged EGR to close wont help much. Just trying to make sense of these Ultragauge numbers.

Have been reading a few threads on Defender2.net where people have cleaned out the entire inlet manifold + EGR and seen a huge improvement in running, wondering if that is another thing to consider.

[Tikka7mm08]

Yes been putting off getting a BAS remap for a while but maybe time I bit the bullet. Even still I want to know the EGR is working properly and not stuck in some weird state, a remap asking a stuck or clogged EGR to close wont help much. Just trying to make sense of these Ultragauge numbers.

Have been reading a few threads on Defender2.net where people have cleaned out the entire inlet manifold + EGR and seen a huge improvement in running, wondering if that is another thing to consider.

I just did that while replacing my glow plugs - posted here somewhere. I didn't notice any improvement. Pulling the EGR might be a good idea and opening up to check the gears?

[DazzaTD5]

*yes economy will go to **** if the egr valve remains open for long periods of time.
*often though it will fault code, but not always, it can also go into limp mode... but not always.
*it can also start blowing smoke if particularly bad.

*When economy is bad, is it blowing black smoke? or is there a heavy build up of soot at the end of the exhaust?

[Lagerfan]

*When economy is bad, is it blowing black smoke? or is there a heavy build up of soot at the end of the exhaust?

No black smoke, well not enough to notice but yes a bit of soot at the end of the exhaust, certainly compared to the other two diesels in the family of similar age.