Down on power
A valve stuck open dilutes the charge and the car feels flat everywhere.
EGR · Daventry
EGR solutions in Daventry.
EGR faults, found in the data.
Sticking valves, flow faults and soot-choked coolers diagnosed with live data — plus EGR solutions for vehicles used exclusively in motorsport and off-road applications.
Live data
not guesswork
Valve & cooler
both checked
Track & off-road
solutions
EGR solutions
What the EGR actually does to your engine
Exhaust gas recirculation lowers combustion temperature by feeding measured exhaust back into the intake. It works — and it also coats the intake tract in soot, sticks valves part-open and clogs coolers, until the engine runs down on power, smokes, or drops into limp mode.
The failure is rarely mysterious. Live data shows the commanded position against the actual position, the airflow deviation that follows, and whether the cooler is leaking. That tells us in one session whether it is a valve, a cooler, a wiring fault, or a genuinely carboned intake that needs cleaning.
For competition and off-road machinery we also provide EGR solutions as part of a properly built file — never as a shortcut around a mechanical problem.
KESS3 · K-TAGGenuine tools, genuine files
Road-use notice: disabling emissions equipment on a road-registered vehicle is illegal in the UK and an MOT failure. EGR solutions are supplied strictly for motorsport and off-road use. For road cars we diagnose and repair.
At a glance
- Commanded vs actual valve position under load
- Airflow plausibility and boost deviation checked
- Cooler leak testing where symptoms point there
- Intake carbon assessment before any work is quoted
- Motorsport & off-road EGR solutions available
The result
Symptoms we see
Smoke and smell
Incomplete combustion from too much recirculated gas.
Limp mode
Position deviation faults trip protection and the car derates.
Coolant loss
A cracked EGR cooler quietly drinks coolant with no external leak.
How it works
Three steps. One visit.
- 1
Book diagnostics
Tell us the symptoms and the sort of mileage the car does.
- 2
We test under load
Live position, airflow and pressure data, not just fault codes.
- 3
You decide
Clean, repair or replace with a clear quote — or a solution for qualifying vehicles.
Good to know
Questions we hear every week.
Will an EGR delete fix my rough-running road car?
It would mask it, and it would also be illegal on the road and an MOT failure. The right answer is finding why the valve is failing — usually carbon, or a wiring/actuator fault.
How often do EGR valves actually fail?
On high-mileage diesels doing short journeys, very often. It is one of the most common causes of the 'flat, smoky, occasionally limping' complaint we see.
Can the intake be cleaned?
Yes — walnut blasting or manual cleaning depending on the engine. We will tell you honestly whether it is worth it at your mileage.
Stop guessing at the EGR.
One diagnostic session usually settles it. Book a slot in the live diary.
Book your slot