Scratching my head!!!!!!

[Caveman2212]

Hi all,  I have trawled to through lots of pages but to no avail to my problem, the EGR VALVE!. I bought the car last February 2015 and had been going really well, btw it's an Avensis T180 2.2.  Earlier this year on a journey I lost all power and car went into limp mode with the VSC and TRC lights on.

Had a look and found that the valve was very blocked with soot as well as the inlet manifold. Cleaned it and disconnect-reconnect on Battery to get rid of the lights.

Then it did it again a few weeks later, then again and again and again etc. Has done it twice this week.

What I do find though now is that there is always a little piece of carbon about the size of a small pea trapped and holding the EGR valve open which then puts it into limp mode and the lights. This is obviously coming from the exhaust manifold and travelling down the pipe to the valve, but how do I stop it. Don't really want to take off the manifold to clean it so want to ask if anyone has had this before.

Cheers for looking

ALAN

(Mod edit - shouting removed)

[JRCorolla2]

If you can take the valve off cant you just completely block it until you have time to have someone look at the scum coming from the manifold? im aware a lot of companys offer a cheap EGR delete service also?

[fordulike]

I'd run a can of this stuff through the intake system, whilst the car is stationary:

Wynn's EGR3 Diesel

Then take it out for an Italian Tune-up to blast all the crap from the system.

Did this on my previous Nissan Almera 2.2DCi every now and again, coz a sticky EGR valve caused no end of engine running problems.

If you're not afraid to run a diesel engine near the red line for an extended period of time, then an Italian Tune-up can be useful for clearing gunk from the engine. You only need to do it maybe 2 or 3 times a year.

[Caveman2212]

Tried the Italian tune up on Wednesday night on way to work and it did blow some out. 4000 revs for what seemed like an eternity up the motorway then on the way home it failed again. ( car probably thought up yours mate). 

I did make a blanking plate on Sunday morning after it had failed and then on the way to the outlaws house it failed again.

took off that plate and my dad is going to bore the centre out and attach a piece of gauze on it so at least it would stop the large bits getting through.

 

[frankie406]

If your egr is blocked your air intake manifold will be worse. Take it off and give a good clean and sick out the ports with an old vacuum 

[Devon Aygo]

Firstly on a T/SR180 engined car you cannot block the EGR flow as it is monitored by the ECU and if there is no flow the car will go into "limp mode" this is to protect the DPNR filter. 

Secondly the little chucks of carbon are most likely not coming directly from the exhaust manifold but forming in the EGR cooler, a coolant to gas heat exchanger bolted to the back of the cylinder head the is an absolute PITA ( takes between 8-10 hours to remove & refit ) to remove but can be cleaned by removing, blocking one end and filling with a strong ammonia solution and repeating until the flushed solution runs free and clear.

There is a fix and a technical service bulletin EG-0041T-0412 which includes changing a whole host of bits updating the EGR system to a type introduced on the T27 Avensis but it is expensive +£2000 at Toyota's own reduced warranty rates.