General EGR does incredible damage to the engine

[crinklebender]

thought i would report this, for any high mileage JTD doblos out there.

My dobby which i pay to have serviced properly failed its Mot last week on emissions at 100,000 miles. It got a 5.2 and over for smoke. (needs to be under 1.5 to pass)

I started taking the air intakes apart to remove the EGR valve and got a shock from all the oil and gunk in the air intake.. Like this (not my car)..

I never saw anything like this..as part of normal running. The EGR was stiff and full of carbon, but was fine after some WD40. took as much pipework as i could from intercooler to inlet manifold and removed all that gunk. Oil change, new filters and redex in fuel.

Then ReMOT and emissions now down to 0.4 . Drives much better now.

Its not on any of the service books or dealer information that the engine is gunking up like this. It should be part of the general information about the car. All that gunk has being getting pushed through the engine and must be having a detrimental effect.

Pretty stupid engineering. If the engine life is shortened then the cost of replacing the engine or entire vehicle prematurely causes more pollution than what the EGR saves about 10 times over.

 

[T14086]

Niall's doblo has done over 400,000 miles without a problem, your issue sounds more like turbo feed pipe.

 

[crinklebender]

Niall's doblo has done over 400,000 miles without a problem, your issue sounds more like turbo feed pipe.

That was what i thought to start with. I did notice oil seeping from turbo feed to sump..or maybes its going the other way.. the garage who deal mostly with private Taxis, said..most of the TD vehicles that come in here have oil seeping round the turbos, theres no point in changing them.

Seems to be considered normal..I noticed the seeping 6 months ago..but no loss of oil, whistle, smoke on idle or lack of boost...after 5000 miles of horsing the doblo around.


reading up on EGR it seems like this gunk is due to the recirculated gases hitting the incoming air and oil from crankcase ventilation.

http://www.jaguarforum.co.uk/viewtopic.php?f=14&t=26991


Nail doblo is used on long distance journeys where EGR turns off. Doblos in the start stop city are constantly on EGR mode. A semi sticky EGR which most are if not cleaned regularly will not interfere with drivability too much and blow in more dirty gas, almost all the time in city driving.

 

[briangoo]

i had a mk2 mondeo v reg 1.8td taxi with the same trouble sluggish & smokey & i did the same, took egr valve off & cleaned it. it was spot on & quicker

 

[crinklebender]

i had a mk2 mondeo v reg 1.8td taxi with the same trouble sluggish & smokey & i did the same, took egr valve off & cleaned it. it was spot on & quicker

The increase in oil round the turbo on all these taxis, might be increased crankcase pressure due to the gunk from the EGR getting shoved back into the engine.

Just guessing though. The taxi garage think the turbos are all fine even though there is oil round them. Ill need to ask them about next time i go in.

 

[T14086]

Nail doblo is used on long distance journeys where EGR turns off. Doblos in the start stop city are constantly on EGR mode. A semi sticky EGR which most are if not cleaned regularly will not interfere with drivability too much and blow in more dirty gas, almost all the time in city driving.

Not strictly true, EGR will operate at low RPM cruising and if you watch the EGR it will be closed at idle, unless requested by the ECU via air flow meter signal.

My 1.9JTD doblo is on its original EGR after 6 years, my tip is to give it a quick blast up a hill every week....don't be afraid to rev it to the limit in 3rd as you look and say goodbye to the smoke in the rear view mirror

 

[crinklebender]

Not strictly true, EGR will operate at low RPM cruising and if you watch the EGR it will be closed at idle, unless requested by the ECU via air flow meter signal.

My 1.9JTD doblo is on its original EGR after 6 years, my tip is to give it a quick blast up a hill every week....don't be afraid to rev it to the limit in 3rd as you look and say goodbye to the smoke in the rear view mirror

To the limit ...what you mean 5000 RPM and above ?..

I never revved my dobby over 3500 in all the time i had it...

I did find the EGR was sticky...but WD 40 and it soon got all springy and responsive again.. (no double entendres meant )

 

[ivantate]

Rev it and dont be scared! no wonder it is clogged, unfortunately the car manufacterers can do nothing about the emissions regulations they have to meet. this is why small engines working harder are being pushed more even if it is to the detriment of fuel economy.

Wait until you have a car with a dpf, that will be clogged regularly if you are having problems now.

The other option for diesels is an scr and urea system but is likely to cost over 3000eur more per car and you need a seperate tank for the urea.


Have you had the crankcase filter replaced? i guess there is one on the jtd. once blocked they can cause problems with turbos and running. they rarely feature on the service schedules (plenty of update bulletins though) i have seen a few doblos with around 100k with failed turbos but unlikely they had been serviced or driven steadily.

If you get another 100k before needing to clean it all again it wont be too bad!

 

[crinklebender]

Rev it and dont be scared! no wonder it is clogged, unfortunately the car manufacterers can do nothing about the emissions regulations they have to meet. this is why small engines working harder are being pushed more even if it is to the detriment of fuel economy.

Wait until you have a car with a dpf, that will be clogged regularly if you are having problems now.

The other option for diesels is an scr and urea system but is likely to cost over 3000eur more per car and you need a seperate tank for the urea.


Have you had the crankcase filter replaced? i guess there is one on the jtd. once blocked they can cause problems with turbos and running. they rarely feature on the service schedules (plenty of update bulletins though) i have seen a few doblos with around 100k with failed turbos but unlikely they had been serviced or driven steadily.

If you get another 100k before needing to clean it all again it wont be too bad!

I tried to check for crankcase filter but nothing came up... Will need to investigate as their is oil seep where the crankcase is meeting the turbo outlet.

something is not right there, either crankcase ventilation or turbo. Ill put it on my check it out before it gets worse list....but at least its passed MOT for now