EGR's are a bane of the diesel owners life these days.
Modern diesels and the emissions legislations they are built too require the engine to "choke" on exhaust gases in the event it runs lean (and hot so it produces more Nitrogen Oxide) like the over run (fuel virtually shuts off and combustion temps rise) or steady light throttle.
The last lot of "interfering" made it a requirement the car's ECU report's emission faults, so they suck a bloody sensor in the things! No more blanking or removing.
What the next legislation is going to be isn't quite clear to us customers yet, but I had heard Mercedes are "touching cloth" over it and considering pulling some of their bigger diesel engines as they're struggling.
Trying not to be bitter (hard for me, I have 3 diesels) the actual reasons behind them aren't total bull, but the benefits aren't as great as is made out, fuel ecomony actually reduces because of them, around 5%.
So we all burn more diesel and produce more emissions because of them!
After messing around with my fair share of them when they've caused issues, there's one, reasonably simple way to extend their life to a more acceptable life.
It's already been referred to by Z11.
This carbon/soot mixture is soot from the exhaust, but it's mixed with oil.
It gets the oil as it's been plumbed in to the air intake from the crankcase breather vent or CCV (yes another emissions legislation)
The hot oily vapour and soot meet at the EGR and decide to take on a new form, nasty gunk that clogs the valve up and inlet manifold/ports to the cylinders.
This is why they all start to fail around the same time as it takes a while for the intake/intercooler to build up some oil from the breather.
I've ran a diesel with a catch tank in between the engine and air intake for two years now and covered 35k.
It's still venting to the air intake and not just out to atmoshere, it just plumbs in, takes the vapour low, through the tank then back up and into the intake as normal.
It's baffled rather than a cheap, ebay can that's empty, so it traps more of the oil and it's designed for diesels with the correct size inlet and exit ports.
It's totally stopped the gunk and I've had no EGR trouble at all.
Soot still builds up slightly, but it's drier and flakes off the valve easily, I've also managed to reduce the size of the exhaust port into the EGR (plate with a hole in it) and this has virtually stopped the soot as well.
It's a common kit for VW TDi's (might be a little large for the Panda bay though) as they can suffer quite badly from oil blowby, but there are tank/filters available from the likes of Parker/Racor, Mann etc.
http://www.allardaluminiumproducts....lf-seat-skoda-audi-tdi-vag-group-engines.html
http://www.parker.com/portal/site/P...&vgnextdiv=687630&productcategory=productline
Ok, rant over!