EGR issue

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

There may be more than one reason for the failures occuring. In my case, hard carbon buildup prevented correct operation. I have heard of at least one other EGR whose electric solenoid went out. What is not clear is why the European CRD's don't appear to have the high failure rate we in the US have. Assuming the European EGR valves are the same as the US models, the only differences I'm aware of is the fuel and the emissions mapping software. All things considered, I'm leaning toward the emissions software causing premature failures. In your case, failures at 300 and 100 miles had to be something other than carbon buildup. I've heard that some dealers were actually cleaning the EGR's instead of replacing them. I hope that's not what they're doing!

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

"Update on my end: a couple of days now with the EGR blocked off, and the P0299 code is back, too. So apparently it *can* happen, Ranger1, even with the EGR pipe closed."

Bizarre. If the boost pressure is being measured and setting the CEL due to low pressure, then I would think the boost pressure is leaking out somewhere between the turbo and intake manifold. Man we need a boost gauge on these CRD's. Hard to troubleshoot without them. Are the turbo hose clamps tight? I have tightened mine about 3 times in 10 months. They seem to loosen up periodically, not a lot, but a little each time. I just check them about every 3 months now just to be sure.

Another possibile leak might be the EGR valve/cooler itself. You would think if it was leaking, the coolant would show some contamination discoloration. I'm going to buy some of that bubble stuff kids use, and spray some on my EGR valve, hose connection points and intercooler this weekend and run the engine to see if anything is leaking, even slightly... this has my curiosity stirred.

greiswig · **Posted:** Wed Jan 25, 2006 10:00 pm

Ranger1 wrote:

"Update on my end: a couple of days now with the EGR blocked off, and the P0299 code is back, too. So apparently it *can* happen, Ranger1, even with the EGR pipe closed."

Bizarre. If the boost pressure is being measured and setting the CEL due to low pressure, then I would think the boost pressure is leaking out somewhere between the turbo and intake manifold. Man we need a boost gauge on these CRD's. Hard to troubleshoot without them. Are the turbo hose clamps tight? I have tightened mine about 3 times in 10 months. They seem to loosen up periodically, not a lot, but a little each time. I just check them about every 3 months now just to be sure.

Another possibile leak might be the EGR valve/cooler itself. You would think if it was leaking, the coolant would show some contamination discoloration. I'm going to buy some of that bubble stuff kids use, and spray some on my EGR valve, hose connection points and intercooler this weekend and run the engine to see if anything is leaking, even slightly... this has my curiosity stirred.

I'll take a look at the hose fittings, etc. soon as I have a chance and report back. I also wanted to put soapy water around that flange and make sure there isn't something leaking from the EGR pipe, but I'd guess it would have to be a pretty substantial leak to cause a code to trip, and I'd have heard the leak.

oldnavy · **Posted:** Wed Jan 25, 2006 10:27 pm

Your intercooler and hoses are not pressurized Ranger1, they have a vacuum from the turbo sucking air through the intake so the bubble stuff won't do any good unless you see it being sucked into the hose. The back side of the turbo to intake is when the pressure is on these babies. I haven't looked to see how much plumbing is from turbo up to intake, but that is where boost gage would be, after turbo.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

On mine, the output of the turbo, what I'm assuming is the pressurized side of the turbo, feeds the intercooler, which should have boost pressure, and it exits the intercooler on the driver side, connected to the engine intake. I'm referring to this plumbing, not the intake plumbing from the air filter to the turbo intake.

oldnavy · **Posted:** Thu Jan 26, 2006 12:09 am

Ranger1 wrote:

On mine, the output of the turbo, what I'm assuming is the pressurized side of the turbo, feeds the intercooler, which should have boost pressure, and it exits the intercooler on the driver side, connected to the engine intake. I'm referring to this plumbing, not the intake plumbing from the air filter to the turbo intake.

I didn't think the the turbo side would have been easy to get at, but I really haven't looked at the engine other then looking about CCV replacement and design. That thing (CCV valve) is a waste of time and effort, I would bet it's only about 20% effective if that much. Maybe this weekend if I am over this killer sinus infection and chest cold I will try to poke around the engine bay a bit.

Yes I have something going on to eliminate more of the oil out of the intake system, something like I did for the VW TDI's on Fred TDI Forum. It was called there the Old Navy CCV filter and was pretty effective at stopping the oil flow to the intake.

greiswig · **Posted:** Thu Jan 26, 2006 12:11 am

oldnavy wrote:

Your intercooler and hoses are not pressurized Ranger1, they have a vacuum from the turbo sucking air through the intake so the bubble stuff won't do any good unless you see it being sucked into the hose. The back side of the turbo to intake is when the pressure is on these babies. I haven't looked to see how much plumbing is from turbo up to intake, but that is where boost gage would be, after turbo.

I don't think this is true. The boost from the turbo heats the air, which is what necessitates the intercooler. Hot, pressurized air goes through the intercooler to reduce the temperature before it goes into the intake. If you were cooling unpressurized intake charge, you'd be cooling ambient air using air at ambient temperature, which wouldn't be much of a gain.

oldnavy · **Posted:** Thu Jan 26, 2006 12:16 am

greiswig wrote:

oldnavy wrote:

Your intercooler and hoses are not pressurized Ranger1, they have a vacuum from the turbo sucking air through the intake so the bubble stuff won't do any good unless you see it being sucked into the hose. The back side of the turbo to intake is when the pressure is on these babies. I haven't looked to see how much plumbing is from turbo up to intake, but that is where boost gage would be, after turbo.

I don't think this is true. The boost from the turbo heats the air, which is what necessitates the intercooler. Hot, pressurized air goes through the intercooler to reduce the temperature before it goes into the intake. If you were cooling unpressurized intake charge, you'd be cooling ambient air using air at ambient temperature, which wouldn't be much of a gain.

Yes I know the intercooler is the on the pressurized side and that after coming through the turbo it can be 250 to 350 degrees F from the compression. I just didn't remember seeing anywhere on the pressure side he could do what he was wanting to do, but like I said I really haven't looked much and have not even look to see how big the IC is or it location in the engine compartment.

greiswig · **Posted:** Thu Jan 26, 2006 12:25 am

oldnavy wrote:

greiswig wrote:

oldnavy wrote:

Your intercooler and hoses are not pressurized Ranger1, they have a vacuum from the turbo sucking air through the intake so the bubble stuff won't do any good unless you see it being sucked into the hose. The back side of the turbo to intake is when the pressure is on these babies. I haven't looked to see how much plumbing is from turbo up to intake, but that is where boost gage would be, after turbo.

I don't think this is true. The boost from the turbo heats the air, which is what necessitates the intercooler. Hot, pressurized air goes through the intercooler to reduce the temperature before it goes into the intake. If you were cooling unpressurized intake charge, you'd be cooling ambient air using air at ambient temperature, which wouldn't be much of a gain.

Yes I know the intercooler is the on the pressurized side and that after coming through the turbo it can be 250 to 350 degrees F from the compression. I just didn't remember seeing anywhere on the pressure side he could do what he was wanting to do, but like I said I really haven't looked much and have not even look to see how big the IC is or it location in the engine compartment.

I *thought* I must have been reading that wrong, oldnavy...it just didn't sound like a misunderstanding you'd make. Sorry! :oops:

oldnavy · **Posted:** Thu Jan 26, 2006 12:39 am

Well I am so dang sick with this head cold/sinus infection at times I can hardly talk or even see. Went to doctor to day and got a Z-PAK, allergy pills and even now my right eye feels like it's about to pop out from all the pressure. Doc told me if he was a Veternarian and I was a horse, he would have just shot me. :lol:

EGR issue

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