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DPF & Diesel

EGR Valve Repair & Replacement

The EGR system recirculates a measured amount of exhaust gas back into the engine. When it sticks, everything downstream suffers — including the DPF.

Rough running or limp mode?

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Symptoms of EGR problems

  • Engine management light with EGR flow or position codes
  • Limp mode or loss of power
  • Rough idle and hesitation
  • Excessive smoke
  • Increased fuel consumption
  • Repeated DPF loading and failed regenerations
  • Coolant loss on engines with an EGR cooler fault

What the work can involve

  • Testing valve operation and position feedback in live data
  • Cleaning carbon deposits where the valve is serviceable
  • Replacing the EGR valve, cooler or associated pipework
  • Renewing gaskets and checking the intake for restriction
  • Clearing adaptations and confirming correct operation on road test

Related work

Heavy carbon build-up in the EGR system usually indicates something about how the engine is running or being used. We look at the wider picture — injectors, boost, cooling and journey patterns — so the problem does not return in a few thousand miles.

Frequently asked questions

Diesel running badly?

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Our work

Recent jobs from our workshop

Photographs taken during work carried out at our Iver workshop.

  • EGR pipe removed showing soot blocking the port

    Soot-blocked EGR port removed for cleaning

  • Inlet manifold removed showing carbon in the runners

    Inlet manifold off — carbon build-up in the runners

  • Inlet manifold ports on a cylinder head coated in soot

    Soot in the inlet ports after high-mileage diesel use

Symptoms

Symptoms that often lead to this repair

Look up what your car is doing and read what it commonly means.

DPF warning light onThe DPF light means soot has built up beyond the level the system is happy with. Whether a drive will clear it depends on why it built up.Read more Black smoke from a diesel exhaustBlack smoke is unburnt fuel. On a modern diesel with a DPF it usually also means extra soot heading into the filter.Read more Car shaking or vibrating at idleIdle is where small faults show up most, because the engine has no load to smooth them out.Read more EGR valve symptomsEGR valves soot up over time, particularly on cars used for short journeys. The symptoms overlap with several other faults, so testing matters.Read more

Related

You may also need

DPF DiagnosticsA DPF warning is the end of a chain of events, not the start. Finding out why the filter is loading up is the part that saves money.Read more Diesel DiagnosticsModern diesels combine high-pressure fuelling, turbocharging, exhaust gas recirculation and after-treatment. When one part of that system drifts, the symptoms usually show up somewhere else.Read more Turbo ReplacementTurbo failure often has an underlying cause. Oil supply, restriction and boost control are checked first — otherwise the new turbo goes the same way as the old one.Read more Cooling System RepairsOverheating is one of the few faults that can turn a modest repair into an engine rebuild in a matter of minutes. Stop and call rather than pressing on.Read more

Talk to us about egr valve repair & replacement

Based in Iver, covering West London, Berkshire and South Buckinghamshire. Send your registration and we will quote for your vehicle.

Call 07440 140340WhatsApp us