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Have realised that under heavy load in nuetral (over 3500rpm) the car is blowing a massive amount of evil looking pure black soot that covered everything including the dog. It is so thick it just lays on everything. Is this consistent with EGR valve stuck open? That would explain why the intake manifold got a hole in in it. I just don't get why there are no codes as it has always thorwn egr codes for previous egr problems.
Took both egr pipes off to inspect the EGR valve positions. Left side is fine. Surprisingly the right side egr is stuck open (with no error codes). This would explains the black smoke and hopefully the loss of power. The hole in the throttle body is directly opposite the right hand egr exit point so it makes sense that the opposite side should melt.
How could that EGR have blown open given that it was not connected to the power? Am I wrong in thinking that the force must have come from the manifold side and there had to be enough force to open it against exhaust pressure. Having the Egr disconnected meant the ECU could no longer close it even if it wasn't mechanically stuck. This is a chinese valve by the way and only about 18months old.
I am still trying to understand how the turbo hose blow off is related.
Maybe the additional pressure from the EGR being open caused the hose to blow.
There being no codes could mean that the right EGR was stuck open when I first disconnected it (bypassed it) but the trouble with this theory is that the car was driven to QLD and back with no issues.
What is the reasoning for taking off the butterfly intake valve?Quote:
Originally Posted by loanrangie
The valve closes to allow gases to flow from the egrs then opens when they are closed, without removing it you are restricting airflow from the filter box.Quote:
Originally Posted by egr victim
Terry lives again!
I had a D3 blanking plate kit laying around so I decided to give that a go. This is the one where the EGR pipe is removed rather than a cutoff blanking plate. Last time I tried it I think I had issues but I think I had removed the butterfly valve from the throttle body as was suggested.
I put it on, this time leaving the butterfly valve in, expecting to have the car to spit the dummy in some fashion. I thought that if this doesn't work the next step is to replace the egr that is stuck open.
I was surprised that the car runs perfectly fine with no error codes.
Anyway I'll see how it goes. I have an emergency kit consisting of a basic code reader and a spare egr valve to plug in if necessary.
A few tips if I may
- when replacing blocked egr's, is to keep the old ones, especially if they are the originals, clean them up, test them to prove they work and keep them in the car as spares or dummies, in a limp home situation you might be able to use them to fool the computer enough to get home.
- check the blanking plugs (the ones where the egr pipe is removed) for vacum/boost leaks cause a smoke test has revealed they both leak at the throttle body. A very poor fit.
- don't do what I did and permanently travel around with a decoy egr plugged in to the computer because you may not know if it gets stuck open (even though that may seem impossible) and you will cause damage.