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I have written this post following a lengthy fight with my pajero which had heavy smoke problems that subsequently turned into diesel knock.

I fitted a egr blanking plate problem solved but i had to get to the bottom of the reason why.

I went through the process of cleaning the egr then eliminating parts by replacing all with original equipment parts to no avail.

The last fault process was to get a vacuum gauge and check the solenoids at the rear of the intercooler.

I connected the vacuum unit to the pipe that leads to the egr and found the vacuum was pulling off the scale therefore fully opening the egr valve all the time. On a test drive the gauge still read the same no matter what revs or speed so with the help geoff i tested his to find that the egr solenoids are supposed to control the vacuum rate according to accelerator position/revs.

Now, there are 2 causes for this not being right.

Firstly, blocked or partially blocked pipes to egr/solenoids

Secondly the solenoids are defective

There is a easy way to detect this problem...

If you disconnect the egr rubber vacuum hose and drive for a few minutes - once the car is at running temp, if you have no smoke or little smoke then it is probable that the egr vacuum pressure is wrong due to said pipes being blocked or faulty solenoid's This is assuming the egr is not stuck open due to being dirty.

Now the procedure is easy to resolve by cleaning the pipes out with an air line. If that doesn't work then the vacuum pressure needs to be checked.

It should read at zero vacuum when cold and when heavy accelerator use is present, (ie flat out), in between these points the egr vacuum differs being at the most when decelerating from high revs, IE when taking your foot off the throttle). If this is not the case then the solenoids may need replacing... this is what i had to do.

Sorry for the long winded post but i wanted to give you the full picture on this

below is a checklist for very smokey pajero/shogun with egr fitted

1 change all filters

2 dirty/contaminated fuel needs to be ruled out

3 egr dirty and requires cleaning

4 egr vacuum pipes blocked

5 egr solenoids faulty

6 injectors not functioning correctly

7 pump timing out

8 pump has been messed with ie turned up following sva /mot emissions test

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Q: Why does my diesel pajero have no power and burns black smoke.?
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