What is an exhaust gas recirculation (EGR) valve?
The EGR valve in your Toyota is fitted within the exhaust system and allows some of the gases produced during the combustion process to be re-burnt within the combustion chamber for a second and more effective time. This occurs when the correct engine operating conditions are met and, in turn, serves to reduce harmful emissions.
What does an EGR valve do?
The process of recirculating precise quantities of exhaust gases back into the combustion chamber has a number of advantages. In petrol engines, it helps to lower combustion temperatures and reduces the chance of spontaneous combustion, also known as knock. This allows the engine control unit (ECU) to dilute the air/fuel mixture and reduce petrol consumption.
In diesel engines, the role of the EGR valve is even more important. Routing exhaust gases back into the combustion chamber also lowers combustion temperatures, but the primary benefit is the reduced formation of nitrous oxide (NOx) particulates. In addition, the reappearance of spent exhaust gases within the combustion chamber enables the engine to neutralise these particulates through secondary burning.
Does the work of the EGR valve relate to the function of the particulate filter in diesel engines?
Yes, but indirectly. The neutralising of NOx soot within the combustion chamber reduces the quantity of this material heading into the diesel particulate filter (DPF) installed further down the exhaust system. This increases the time period between regeneration procedures and the service life of the DPF itself.
Why might an EGR valve fail?
Its location within the direct path of flowing exhaust gases means that soot can accumulate around the EGR valve and block its free movement. It is possible to mitigate this by ensuring the vehicle is regularly driven at sustained speeds above 40mph. Constant use of any vehicle in low-speed, urban environments with frequent stops will accelerate the amount of soot collecting around the EGR valve.
How can I tell if the EGR valve in my car is failing?
A failing EGR valve will affect the performance and economy of your engine, though it is likely that the ECU will notice the issue and alert the driver through a dashboard warning light before any physical symptoms are experienced. These symptoms may include rough idling, hesitance in acceleration and a loss in fuel economy.
What do I need to do if I see the engine check light illuminate?
Return the car to your main dealer to be checked. If the fault code displayed by the diagnostic equipment relates to exhaust gas recirculation, the likelihood is that the valve will need to be either cleaned or replaced. Cleaning is much cheaper than replacement, so it is prudent to react immediately to all warning lights.
Verso 1.6D June 2016. I was booked in today to have my EGR valve replaced. I have already waited 3 weeks for this and was assured that it would be fitted this time. Having had the car returned today after its 1st service I find that the valve has not been replaced and the dealer says that they do not know when it will come in. I am driving around with the management light on and limp mode part of the time. How long will this be? My car is only 9 months old. At Easter I will be holidaying in the car and need it sorted by then. Toyota GB – When will the EGR valve be available? Will Toyota GB be loaning me a car if this continues much longer?
Hi I had the same problem under warranty, dealer useless. The best way to clear it is to take it on a fast road in forth gear and thrash it for a few minutes it seems to blow it through.
Paul, thanks for your advice. If I can get it out of limp home mode long enough I will try that.
Having exactly the same issue…
Hi Matthew,
Have you reported this issue to our Toyota GB customer service team?
Ella, how would I do that? Can I have the contact details please? Thank you
Hi Matthew,
You can contact customer relations here: https://www.toyota.co.uk/contact-us.
My 2010 Prado lights start flashing on any long trip. I took it to the dealer who says the EGR valve need replacing. Is it possible that this can take 5.30 hours labour?
Hi there,
Our dealers have years of experience and they will be giving an accurate quote for both price and time requirements. We would have to suggest speaking with customer relations if you would like to query this further or keep in touch with your dealer. 🙂
My Toyota Prius (2011) after 60,000 miles got warning sign lit up on the dash. I booked diagnostic at a certified Toyota service, by the time I got there, the sign disappeared.
I did the diagnostic anyway and was told that EGR (exhaust gas recirculation) valve is failing (more like foiling). The quote for replacing it at Toyota is almost 600 GBP, no other recommendation was given or reasons for the valve failure was explained.
A few months later the sign came back again, with the same signal – the car is loosing power when idling. EGR works by recirculating a portion of an engine’s exhaust gas back to the engine cylinders. I called to Toyota service again and asked them to book me for the valve replacement, they stated that diagnostic is first (each cost 60 GBP) and only then ordering parts.
I asked them to replace it and if the warning sign will still be there we think about the diagnostic. They refused.
Digging into the forums, the EGR clogs up because exhaust gas is not recirculating back into the engine at idle, and generally only happens when the vehicle exceeds 30 mph. Which for city cycle is almost never. Last time the sign disappeared as I was driving 20 miles to the centre on the motorway and helped to clean the valve.
Replacing the valve every 60,000 miles for 600+ 60 GBP is a bit excess or flaw in design (particularly for hybrid). I talked to the service station, apparently checking EGR is not part of any service, they do not clean them..just making money… Have you experienced this on your Prius and other any alternative solutions?
Had this on a new Avensis D4D Same story from dealer Solved by using £3 worth of Carburettor Cleaner, removing valve (6 bolts), opening egr (3 bolts) and spraying it clean Also clean the inlet port to exhaust with a strong wire and carb cleaner I do it every service and it is perfect
This is obviously a re occurring problem that Toyota have not dealt with and are loosing customer loyalty over not dealing with this matter properly!
I have a 2016 Toyota Avensis which is less than a year old with the same problem. Toyoto have it at the moment and told me they have never seen this problem in a new car. My car seldom does town driving as I work 40 miles away and the journey is mostly dual carriage way. It went in twice before the problem was identified and my last journey home resulted in 3 stops to try and recover the loss of power. This is my 2nd Avensis and my 2013 model was lovely. Don’t think there is going to be a 3rd. 🙁
I also have a 2016 Avensis, it had 2 EGRs in the first year. I do mega mileage so it’s not caused by round town trips.
Both times it has been repaired under warranty and I have been given a hire car.
Hi Peter,
We’re sorry to hear this. Have you spoken to customer relations about this issue?
Hi Ella,
Many thanks for your swift reply. Indeed, I did, hence there is post.
However your attention only partially answers the question.
Two other parts:
– Design issue.
– Checks while servicing the car (20,000 miles, etc..)
Hi Peter,
Please could we take your case number for this complaint?
We will feed back all of your comments regarding the design and checks whilst servicing. Unfortunately, we’re unable to comment on whether these will be implemented in the future. All comments regarding design are monitored by specific teams around the company and logged accordingly.
Ella, I am sorry but I do not understand your reply. You writing that everything is taken care of but no material change to this particular issue in any shape of form. While it sounds re-assuring from public relations point of view, I would like to have resolution. Alternatively the case is open. I do not want to publish may case number, as it is the only Toyota Service in 40 miles radius and I need the service in the future.
You will not be able to drop 600 pounds price for a simple valve, as far as the complaint, I am afraid it will compromise quality of service for me personally in the future. You see I am afraid.
Hi Peter,
In order for us to move forward with your case and speak to customer relations about your issue we require your case number or email address. We won’t make these details public.
With regards to other issues you addressed, we pass these comments on to relevant people around the company and then it is out of our hands.
Ella,
Unfortunately you reply below does not include option for a any response. You will not be able to drop 600 pounds price for a simple valve, as far as the complaint, I am afraid it will compromise quality of service for me personally in the future. I hope you understand.
I am also would welcome feedback from the design and maintenance team.
You have been very lucky with your dealership. Mine only suggesting doing diagnostics everytime and replacement. With lack of any meaningful support or advice on how to deal with it either from dealership or Toyota blog, I did some research. I bought cleaning solution and add it into the gas tank. After driving 100 miles, the sign disappeared Exhaust Gas Recovery (EGR) on my Toyota Prius. Such a shame that we appear to be a milking base, rather than part of the family.
Hi Peter, could you please tell me which clsaning solution you used?
I have a Toyota landcruiser 200 series can someone tell me where the EGR flow bank 2 is situated in the motor I think someone told me it was down in the valley part of the motor
Hi Barry,
We’d recommend speaking with a technician in your local Toyota dealer. They will be the best people to advise.
My Prado has had it’s EGR valve cleaned by sandblasting it and is work fine again. The agent tells me this is a temporary solution but time will tell. The vehicle is used mainly for long trips and only experienced the problem after 150km travel or more.
I have today picked up a 6 month old Auris with 5500 miles on the clock. It broke down on the way home with this defective valve issue. What I need to know is at what point is the repair or part defective. For instance, if it goes wrong in another 5000 miles will I pay again? Or should the new component/repair be good(guaranteed) for a given amount
Of miles?
Hi Kevin unfortunately no luck with Toyota on this mine failed under warranty and it’s always someone else’s fault! They obviously have a problem that they won’t address my last 3 cars have been new Toyotas my next car won’t be
Hi Paul,
We’re sorry to hear this, unfortunately this is a wear and tear part and therefore not an issue with the manufacturing of the product. Do you have a case with our customer relations team?
What is reasonable wear and tear whilst still under warranty?
Given up with lack of customer care
Hi Paul,
The 5 year warranty covers any mechanical fault caused by a manufacturing defect, not natural wear and tear of a vehicle. The location of the EGR valve and DPF is within the direct path of flowing exhaust gases. This means that soot can accumulate around the EGR valve and block its free movement. Therefore, unfortunately not a manufacturing defect and solely a wear and tear issue with the car. We would have to recommend speaking with our customer relations team to discuss this further and we would be happy to pass your details on if this is something you require. Many thanks.
typical response from Toyota ” wear and tear” my ar^e. The EGR is clearly not fit for purpose. Are they suggesting that if you live in or near a city you shouldn’t buy a Toyota as the average speed in London is around 11 mph so how can you expect to achieve 40 mph….If it needs repairing/replacing after 5000 miles then as I said its not fit for purpose and I would love for this to be challenged in the courts. Although mine was replaced under warranty as the car was less than a year old.
Hi Malcolm,
Thanks for your comment. The purpose of the EGR and DPF filters is to meet emission targets set by the EU to all automotive companies. If you wish to discuss this further, we’d suggest contacting our Customer Relations team. You can find their details here: https://www.toyota.co.uk/contact-us/index.json.
Many thanks.
Hi Kevin,
We would recommend speaking with your local Toyota Centre about this, they will be able to discuss this in more detail.
Thanks for the reply, but without wishing to be provocative, it seems a little evasive. Surely there is a policy on this?
Hi Kevin,
As explained above in the blog post the EGR valve’s location within the direct path of flowing exhaust gases means that soot can accumulate around the EGR valve and block its free movement. It is possible to mitigate this by ensuring the vehicle is regularly driven at sustained speeds above 40mph. Constant use of any vehicle in low-speed, urban environments with frequent stops will accelerate the amount of soot collecting around the EGR valve. As the fault is not due to a manufacturing defect, it will not be covered by warranty. Therefore, a customer would need to pay for this. If you need further clarification on this issue, we would recommend contacting Toyota UK customer relations team.