I just installed my Autometer Boost gage, hence I needed to remove my intake to drill, tap and clean. That whole process only took about 35 minutes. But what I did find was a little unsettling. I wasn't but now I am leaning toward an egr plate and a Finger stick. Also if I go this route, by by kitty! I would tend to believe that the intake should be spotless, or at least not this dirty.
Here are some pics of the intake. You be the judge... EGR should we block them.
Truck has 7500 miles on it.
Note pics are rather large. I left them this way so you could see better detail.
Intake1 (http://www.petefredette.com/Intake1.JPG)
Intake2 (http://www.petefredette.com/Intake2.JPG)
Intake3 (http://www.petefredette.com/Intake3.JPG)
Intake4 (http://www.petefredette.com/Intake4.JPG)

Nice pics. to me it makes sense, soot and egr can be nothing but bad news. dirt, dirt, dirt, it does hurt. that sucks but thanks for the pics.

When I installed my plate at 5000 miles I removed the intake tube just out of curiosity. I was amazed at the amout of soot build up.http://www.dieselplace.com/forum/images/smilies/Throwup.gif I told my brother when he picked up his 2005 to unplug the EGR drive it home and install the plate. I only wish I could have known about this sooner.

the egr is the worst thing they could put on a diesel. i hate it

gawd..is that what my intake pipe is going to look like when I remove it?? geeeez

no wonder the oil gets so dirty so quickly

I was a little hesitant at first to block mine off, but after seeing that I am glad I blocked it when I did! :eek:

Is there any way to clean that mess up, solvents , brushes, scraping? Or do we just have to live with it that way?

Now that there's nasty, I don't care who ya are, thats nasty! -:t

By the way, thanks for posting the pics.

Dennis

Oh damn. Maybe I had better get that blocker plate... That is thicker than I expected it to be. Did you scratch into it and measure how thick it was? Nasty...

Oh damn. Maybe I had better get that blocker plate... That is thicker than I expected it to be. Did you scratch into it and measure how thick it was? Nasty...I didn't want to disturb what was in the intake area. I did clean the manifold. It wasn't to thick, just a little oily. Cleaned up good in the parts washer.

I have my blocker plate waiting for the truck to be built. I'm driving it home letting it cool off and putting the blocker plate in and installing the 4'' straight pipe. Hopefully with less than 20 miles on the truck:D .

Are there any potential problems with putting th egr blocker plate? Could it possibly do any damage to the truck down the line, maybe at 100,000 miles. I know that all of that soot isn't great, but I just don't know enough about how the EGR works, so looking for education. Thanks.

Great Pics Thanks for time and effort. Wow is this what they mean by Warranty issues? What were they thinking.
Thanks for the Plate and Finger stick ! How do you go about cleaning this out Withtrying to take the whole engine apart?
Thanks again

I was told the crankcase breather is also right there at the intake so alot of the oil buildup is coming from it. When I saw mine, my first thought was I'd lost a bearing in the turbo. So I pulled off the boot on the turbo and it was clean as a whislte Whew!

I was told the crankcase breather is also right there at the intake so alot of the oil buildup is coming from it. When I saw mine, my first thought was I'd lost a bearing in the turbo. So I pulled off the boot on the turbo and it was clean as a whislte Whew!When I had the boot off from the intercooler return pipe to the intake, it was a little oily, but clean as in no soot.
It all started where the egr comes into the intake as seen here:
http://www.petefredette.com/Intake3.JPG

All that soot makes them look like exhaust manifolds instead of intake manifolds.

After looking at those I'm blocking the EGR and finger stickin it.

Thanks for the pics Pete.

Thanks for the pics. I'm glad I decided to use the finger plate. There has got to be a better way to cut down on emissions than an egr on a diesel. Hopefully gm realizes this and can find a better way. Cummins doesn't need an egr.

Cummins doesn't meet the upcoming standard either. The Dmax does.

Where can I get the blocker plate and fingers.

Where can I get the blocker plate and fingers.

http://dieselplace.com/forum/showthread.php?t=24719



http://dieselplace.com/forum/showthread.php?t=21428

How do I get that blocker plate? I have a new 2005 2500HD Duramax EGR Mod (Plate & Stick) ?:help: :help2:

The Exhaust Gas Recirculation (EGR) System is used to reduce the amount of nitrogen oxide (NOx) emission levels caused by high combustion temperatures. At temperatures above 1 371°C (2,500°F), oxygen and nitrogen combine to form oxides of nitrogen (NOx). Introducing small amounts of exhaust gas back into the combustion chamber displaces the amount of oxygen entering the engine. With less oxygen in the air/fuel mixture, the combustion pressures are reduced, and as a result, combustion temperatures are decreased, restricting the formation of NOx.

The EGR valve motor is a direct current (DC) stepper motor utilizing a worm gear that extends from the motor to push on the EGR valve stem. The worm gear is not attached to the valve stem, and can only force the valve open. A return spring is used to force the valve closed.

The mass air flow (MAF) sensor signal is used by the engine control module (ECM) to detect the proper amount of EGR flow. One EGR flow test is performed per ignition cycle. The ECM will close the EGR valve for 5 seconds, then open the EGR valve to 100 percent for 5 seconds. The ECM will then calculate the MAF difference and determine if the proper EGR flow has been detected.

The exhaust gas recirculation (EGR) valve is controlled by the engine control module (ECM) through the EGR motor high control and EGR motor low control circuits. The ECM supplies voltage that is near ignition voltage to the high and low control circuits at all times. This voltage is used by the ECM as a reference voltage during non EGR operation in order to detect circuit failures. The ECM will pulse width modulate (PWM) the low control circuit to ground and an increase in amperage on the high control circuit can be observed with a DMM when the EGR valve is commanded open. A lower pulse width will increase the open position of the valve. In order to close the EGR valve, the ECM will PWM the high control circuit to ground.

When the ignition is turned ON, the ECM will drive the EGR motor worm gear out with just enough force to touch the EGR valve stem. The ECM will do this 3 times in quick succession. This action determines the minimum closed position of the valve and only happens once per ignition cycle. If the valve is prevented from closing all of the way after the minimum closed position is learned, the scan tool EGR Position parameter will not reflect this position until the next ignition cycle. The EGR motor worm gear is not connected to the EGR valve stem and can only push the valve open. The valve is returned to the closed position by a return spring.

The ECM uses the EGR position sensor to determine the position of the EGR valve. The ECM sends a reference voltage through the 5-volt reference circuit to the EGR position sensor. The ECM provides a voltage return path for the sensor through the low reference circuit. A variable voltage signal, based on the EGR valve position, is sent from the sensor to the ECM through the EGR position sensor signal circuit.

EGR Valve Control Enabling Conditions.

Exhaust gas recirculation (EGR) valve control will only be enabled during idle and cruising conditions while the following conditions are met:

<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>The intake air temperature (IAT) is more than 5.25°C (41.5°F). EGR valve control will remain enabled until the IAT is less than 0°C (32°F) and will not enable again until the IAT is more than 5.25°C (41.5°F). </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>The engine coolant temperature (ECT) is between 60-96.75°C (140-206.15°F). EGR valve control will remain enabled until the ECT is less than 57°C (134.6°F) or more than 99.75°C (211.55°F) and will not enable again until the ECT is between 60-96.75°C (140-206.15°F). </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>The barometric pressure (BARO) is more than 74 kPa. EGR valve control will remain enabled until the BARO is less than 72 kPa and will not enable again until 74 kPa. </TD></TR></TBODY></TABLE>