Tech Tips

EGR Troubleshooting basics

Exhaust gas recirculation (EGR) is a reliable and practice-proven method of emission control. As a result of
exhaust gas, the oxygen content in the air-fuel mixture is reduced and the combustion temperature in the
cylinders are lowered. Pierburg explains the basics of EGR systems and some basic troubleshooting.

S ince harmful nitrogen oxides (NOx) are

mainly produced at high temperatures and
pressures, it is possible to reduce the NOx
EGR system components
1
concentrates emitted to the environment by up
to 50% by lowering air intake temperaure. On
2
diesel engines, the formation of soot
particulates is lowered by approximately 10%. 5
Exhaust gas recirculation is only activated 3
at defined operating points. On petrol engines
this is normally the case above idle, up to 1 Air filter 6
upper partial loads. On diesel engines the EGR 2 Air mass sensor
is active up to approximately 3000 rpm and 3 Throttle valve/control flap
medium load. 4 Cylinder
5 EGR valve (pneumatic example) 7
EGR Components 6 Electropneumatic pressure transducer 8
The EGR valve meters the amount of 7 Lambda/O2/Oxygen Sensor 4
recirculated exhaust gas. It is added either at 8 Catalytic converter
the exhaust manifold or at the intake air
system, or it is located in a heat resistant
exhaust-gas pipe, which connects the exhaust
manifold to the intake air system. worn valve stem seals or guides, the use of vacuum controls (vacuum pump, vacuum lines
Pneumatic EGR valves are actuated by unsuitable engine oil qualities or an excessive or solenoid valves).
way of vacuum via electromagnetic valves. On engine oil level. Exceptionally intense deposits Electric EGR valves and solenoid valves
basic systems with an electric switchover valve, may also be caused by faults in the injection can mostly be actuated by way of an actuator
the EGR valve only has an open-close function. system. diagnosis by the engine tester. The switching
On systems provided with an electro- Though EGR valves are designed for the of a functioning valve can easily be heard
pneumatic pressure transducer (EPW), the EGR high temperatures in the exhaust branch when the engine is at a standstill.
valve is infinitely adjustable. The vacuum is system, heat damage to the valve may Whenever a new EGR valve is installed,
taken from the intake manifold or generated occasionally occur. Such damage can be and the vehicle behaves as if the valve had not
by a vacuum pump. Electric or have been replaced at all, the
electromotive EGR valves are actuated map data required for operation
directly by the control unit and no must first be "re-learnt". This is
longer need any vacuum or solenoid achieved either in the course of a
valve. longer test drive or by using a
specific programme option in the
Tips for troubleshooting engine tester, e.g. "Basic
The most common cause for settings".
malfunctions in the EGR system are We strongly advise
stuck or carbonised EGR valves. against cleaning EGR
Besides gaseous pollutants, components. If a component is
recirculated exhaust gas also contains already defective, no
soot particulates, particularly in diesel Diesel EGR valves have large cross-sections because of their high return improvement will be achieved by
vehicles. Due to oil in the intake air, rates. LtoR: Pneumatic, Pneumatic EGR valve with position detection and cleaning it. And if functioning
carbon deposits or carbon fouling are an Electric EGR double-seat valve components are treated in this
caused, which foul the valve until it way, they may be damaged as a
can no longer open, or it remains in its open caused by incorrect actuation, excessively high result of cleaning. A defective component
position. This results in jerking, irregular idling exhaust gas back pressure or a blow-off/waste should always be replaced by a new one.

See page 54 for a more detailed EGR

or insufficient engine power. gate valve of the turbocharger which does not

troubleshooting guide
The causes of a high portion of oil in the open. There may even be some manipulation
intake or charge air may be malfunctions in the to increase the boost pressure.
crankcase ventilation, worn bearings, a On pneumatic EGR valves, one potential
clogged oil return line on the turbocharger, cause of malfunctions can be found within the

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EGR Troubleshooting Table

Continued from page 52.

Troubleshooting in exhaust gas recirculation system

Complaint Potential causes Remedies
Caused by EGR valve
• Irregular idling
• General: Coked/stuck EGR valve • Check engine controls
• Jerking
- Poor, inadequate combustion • Check software update of engine control unit
• InsuȰcient engine power
- Engine management fault • Avoid frequent short-distance drives
• Limp-home operation
- Frequent short-distance drives • Replace valve
• MIL lights up/error code set
- Leaks in vacuum system
• InsuȰcient engine power in
lower rpm range or in cold
• Defective solenoid valves • Check function, electrical actuation and
run (3HWURO)
• Malfunctions in vacuum system tightness of vacuum system
• InsuȰcient engine power in
See below: "Vacuum system"
upper rpm range (diesel)
• High oil content in intake or charge air: • Check oil separator, engine exhaust valve
- Malfunctions in crankcase ventilation • Check pistons, piston rings, cylinders, valve
- Engine oil level too high stem seals and/or guides for wear
- Low-quality engine oil • Check turbochargers for clogged oil return line
- Worn valve stem seal or guides • Change of oil and oil filter replacement
(by professional)

• Check sensors for set-point values,

• Air mass sensor signal/other sensor signal defective replace if necessary

• P0401 "Flow rate too low" • EGR valve does not open or is not actuated • Check connectors and actuation
• P0103 "Air mass too high" • EGR system has been EODQNHGGHIHDWHG

• P0402 "Flow rate too high" • EGR valve does not close/remains permanently open • Replace EGR valve
• P0102 "Air mass too low" • Uncontrolled, permanent exhaust gas recirculation • Check connectors and actuation

• EGR valve has temperature
• Incorrect actuation • Replace EGR valve

damage, visible discolouration, • Exhaust gas back pressure too high • Check actuator of EGR valve
initial fusing (3HWURO • Blow-oȭ valve of turbocharger does not open • Check exhaust gas back pressure
• Check blow-oȭ valve of turbocharger
("waste-gate") and its actuation

• New EGR valve, inoperative • New EGR valve has not been adapted • Conduct a basic setting of EGR valve
• High idling after installation using the engine tester
Caused by vacuum system/solenoid valves
• Engine "chattering"
• Defective hoses (porous, damaged by YVKLU[ bites) • In the event of damage, check the tightness
• Engine misfires
• Leaking connectors on pneumatic valves of all components in the vacuum system and
• Limp-home operation
• Leaking non-return valves/vacuum reservoir replace defective partV
• Decreasing braking
• Defective/porous diaphragms or seals on
performance
pneumatic actuators
• Leaks in intake manifold

Caused by air mass sensor

• P0401 "Flow rate too low" • Air mass sensor damaged/dirty due to • Avoid any intake of water and particles
• Black smoke - Dirt particles in intake air into intake air system
• Inadequate engine - Leaks in intake air system, splash water
performance - Contamination during air filter replacement
• Limp-home operation - Clogged air filters
- Oil-moistened sports air filters

• Damage to turbocharger • Check turbocharger

EGR = Exhaust gas recirculation; MIL = Malfunction Indicator Lamp

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