Can't thank you enough for your video. I filled my egr cooler with dpf cleaner (2 cans with flexible tubes [sealy dpf]) from both ends (throttle body and egr valve), but left it in situ. A nylon pipe brush was used to scrub it out as much as I could. It soaked for an hour. I should have syringed it out but I used kitchen towel instead, although I was careful not to drop any paper back in. The result is the box is as clean as a whistle and the warning light has stayed off since then.
Hi Robert. I have the 1.6 DTL. I avoided this build-up by removing the oil gases from the camshaft cover to a decanter or oil collection tank and placing a metal gasket at the EGR inlet, in which we reduce the passage of exhaust gases to a hole of only 8 mm in diameter. There is no DTC fault, the engine gains at low revs, and no part of the intake system gets dirty with oil and carbon. If we leave the system AS STANDARD, the sum of oil and carbon will sooner or later clog the EGR, the cooler, the electric air passage butterfly and the MAP sensor as we see in your video. After 9 years and 198,000 km I have hardly any dirt (from time to time) I remove and observe the turbo inlet pipe, the throttle valve inlet, and the MAP sensor and it is almost clean. It is worth it Robert. Greetings
I have the exact same problem on my astra k , bought a 2nd hand cooler to clean then I will swap over the ends . Mines done 90k miles. I did fit a catch can a couple of years ago but took it off. I took the rocker cover to turbo rubber pipe off and rerouted it through the catch can and back to the turbo again. Its doable with alloy fittings and silicone hoses. It does trap a fair bit of water vapour and oil .
Hi, Thank you for your video. How easy/hard is it do remove the egr cooler? Can you please make a short video explaining what needs to come off and which bolts to undo? Is it all accessible from the top? Kindest regards
Hi Robert. Thanks for posting this. I have an Astra K with 98000 miles that occasionally flags a P0401 code. I clear the code and it stays away for some time but I will need to to something more than cleaning the MAP sensor periodically. As you have shown I too think the culprit is the EGR cooler and a good clean is probably on the horizon! Does this job require any specific tooling, is there anything to watch out for, new seals etc or any recommend removal steps? Any pointers gratefully received.
No special tools, fairly easy, just time consuming. I put mine in a tub of pure tfr for days, periodically removing flushing through and compressed air, then back in. I had a spare, so took my time.
I'm having exactly the same problem and I am also having a problem with constant regeneration on the DPF!! These engines are terrible in my opinion I've had nothing but problems with mine!! Euro6 engines seem to be far mare problematic than euro5
