EGR valve disablement

PROFESSIONAL PROBLEM SOLVING

EGR VALVE AND EGR HEAT EXCHANGER

Complete high-quality service to restore or disable the exhaust gas recirculation valve and EGR cooler of Passenger cars. Solving problems from experts in this matter.

WE CARRY OUT A FULL SET OF WORKS WITH THE EGR VALVE

  • DIAGNOSIS OF A FAULTY EGR VALVE
    Find the exact cause of system failure and return it to working condition
  • DISABLE EGR
    A full range of work, including mechanical blocking of the exhaust gas supply (or complete removal of the EGR valve) and reprogramming of the engine control unit.
  • MECHANICAL CLEANING
    Cleaning a blocked EGR valve and restoring functionality
  • HEAT EXCHANGER (COOLER) EGR
    Solving problems with a leaking EGR heat exchanger or completely removing the cooler and installing specially made plugs
Below there will be a detailed description of the system, the reasons for failure and options for solving problems, which will help you decide on the choice of the necessary procedure. No time to read? Just call or write and we will help you choose the best option.
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DETAILS ABOUT EGR VALVE

Purpose of the EGR valve
All modern diesel and gasoline vehicles are equipped with an Exhaust Gas Recirculation valve, commonly known as EGR or AGR. This mechanism is a part of both the intake and exhaust systems and is designed to reduce the combustion temperature of the fuel-air mixture in the cylinder (by reducing the amount of oxygen) to decrease the amount of NOx (nitrogen oxides) in the exhaust gases and improve environmental performance. Additionally, a secondary cycle of burning part of the exhaust gases in the engine occurs, which theoretically should positively impact the environment. It works simply: the valve directs a portion of the exhaust gases from the exhaust manifold to the intake manifold, where they mix with fresh air and re-enter the engine.

Problems with the EGR valve

Despite its apparent simplicity, the EGR valve is a rather complex and sensitive mechanism. It operates in a very narrow range of speeds and loads, and its incorrect operation leads to big problems. Signs of a faulty valve:

  • “Check engine” symbol on the instrument panel (also a spiral on VAG cars).
  • The car begins to jerk violently, smoke, and stall.
  • There is a sudden loss of traction or constant jerking when accelerating.
  • Jerking on a cold engine that disappears after warming up, or, conversely, jerking on a hot engine, while on a cold engine everything is normal.
  • An accumulation of dirt in the engine intake system.
  • Fuel consumption increases sharply.

Why does EGR fail? It's simple - in 90% of cases it becomes clogged with resins and deposits contained in exhaust gases. In other words, the cause of failure is the dirt that it itself creates inside the engine. 10% is due to wear or problems with the EGR electronics. Where does dirt come from? Some of the exhaust gases return to the intake manifold, cooled in the heat exchanger, and just during cooling, a thick layer of tar deposits begins to grow. It is EGR that creates all the dirt that can be observed in the intake manifold, which leads to a significant deterioration in engine power characteristics, as well as failure of the swirl flaps in the intake manifold. Also, most EGR valves have their own radiator (heat exchanger) to cool the incoming exhaust gases, which begins to leak and leads to a constant leak of coolant. As you can see, this valve creates quite a lot of problems.

SOLUTION OPTIONS for EGR PROBLEM

Replacing a faulty valve with a new one

The easiest option is to simply replace the faulty EGR with a new one. Plus - the system works again. Disadvantages - as before, all the dirt from the exhaust gases will enter the engine and clog the intake manifold, the problem will repeat in the future, the price for some models can be more than 1000 euros, and replacement of car parts due to complexity can cost a significant amount. Also, some cars have 2 valves and require pair replacement.

Mechanical cleaning EGR

The second method of solving the problem. By deep cleaning using special chemicals, complete restoration of the valve’s functionality is achieved (if the malfunction is caused by clogging). This procedure has different costs, which depend on the design of the valve and the complexity of its removal/installation. Performed with complete dismantling of the valve. Pros - restoration of performance, cons - recurrence of the problem in the future, further entry of dirt into the engine.

Disabling or Removing the EGRvalve

The most effective way to solve the problem once and for all. When the EGR valve is removed or blocked, this system is completely disabled, the valve is mechanically locked in the closed position (if necessary) and the engine control unit is reprogrammed to operate without this system. Plus - you solve the problem with this unit forever, clean air enters your engine, there is no more dirt and deposits in the intake manifold, on the valves and cylinder-piston group, power increases slightly due to the combustion of a clean air-fuel mixture, without exhaust impurities. Cons - increased NOx, in some cases it is also necessary to remove the DPF. The rest (smoke, impossible to pass maintenance, etc.) are a consequence of poor quality work. Also, the advantage of disabling the EGR valve is the ability to once and for all solve the problem with the EGR cooler by completely removing it.

EGR valve shutdown: Ecology, Black smoke, Inspection
Some encounter problems after removal — the car starts to smoke heavily, throws errors, and cannot pass the technical inspection. The problem does not arise because the filter was removed, but as a result of turning to amateurs, based on the principle "where it’s cheaper, that’s where I’ll go". By turning to specialists, you are guaranteed to be protected from such "bonuses". There is a huge difference between modifications done by professionals who use proven solutions and amateurs who use "switches" and sometimes do not understand at all what and how to do. Reworking the job after such a "service" sometimes costs many times more than doing everything right initially. Given that the injectors and turbo are in good condition, there are no problems passing the technical inspection. It is important to remember that sometimes minor savings lead to greater expenses of money, nerves, and time than the work of a qualified specialist. Below is an example of our work.

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