QUOTE (three5 @ Sep 13 2009, 10:19 AM)

QUOTE (anchorman @ Sep 12 2009, 10:50 PM)

I suspected mine certainly wasn't any better from the day it was done and only credited better ful consumption to improving weather. As a matter of interest I took my EGR off the other day and although it was sooty as you might expect inside an exhaust, I wouldn't call it carboned up. I don't know how much is down to the flash, how much is down to only high grade fuel and how much is down to fresh oil at regular intervals???
I gave it a flush out with carb cleaner and it looked like new. I can life with the fuel consumption if it behaves in other ways.
Anchorman,
are you going to write up ( pictures? ) your EGR removal and clean? Personally, it sounds like excellent preventitive maintenance and something that I would be happy to do. Can't remember if I've said this before, but my brother and I both bought identical XT5s at the same time from the same dealer. Mine runs on Shell almost all the time and his runs on the weasely stuff from the supermarket. As they have done very similar mileages I am tempted to do both vehicles and see if there is any difference in carbon build up. It would hardly be definitive evidence, but it would be an interesting "indication". How many miles have you got on yours now?
Hi Chris
I would also be very interested in your comparison of the two EGR valves. Mine has done about 22k and has run on almost exclusively high grade diesel and I was expecting the carbon to resemble the hard crusty stuff that you get in the upper cylinder but in fact it was quite soft, more like soot. Here is an over view of cleaning the valve;
Start by pulling the plastic cover off. Obviously the exhaust needs to be quite cool as it is very dangerous when hot.
You need to start by removing the plug from the EGR valve. Squeeze the clip and pull off the connector;

Now with a 12mm socket, undo the two bolts on the cylinder head;

.....and the two on top of the EGR valve;

Be careful not to drop the gaskets and lift the pipe off. Next undo the two remaining bolts in the top of the EGR valve;

As the bolts are flanged, I had to just remove the two bolts in the cover and wiring harness mounting bracket to allow them to clear;

Now lift off the valve. This is the engine side;

......and this is the upper inlet;

You can see the carbon inside. I then used an old paintbrush and a tin of carburettor cleaner to wash out both sides of the valve.

My camera battery went flat so I cannot show the finished result but I can tell you that with little effort it was nearly as bright and shiney as the outside. This photo is of the opening into the inlet manifold. I didn't bother with it because I didn't want to get carbon inside the manifold and given how soft the sooty deposit was I reckon the whole of the inside of the manifold would be similar and it was not hard enough for build ups to cause an obstruction;

The main thing is that I believe I have cleaned enough out to eliminate or reduce the risk of the valve sticking. When refitting the valve I just cleaned all of the mating surfaces with a light rub with wire wool (it comes clean very easily) and the whole job took no more than 20-30 minutes. Refitting is just the reversal and don't forget to pop the plug back on before the ignition is energised or it will throw up a fault code.
For those that don't fancy doing it, don't worry too much as it is covered by an extended 5 year or 100,000 mile warranty but I considered it a kind of insurance policy rather than risk it sticking and having to "limp" home. In the event, I doubt it would have stuck because the carbon was so soft but it will be interesting to see your comparison Chris as it will tell us more about the risk.
Cheers