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Just wondering if anyone here has opened up their intake, or pulled out the EGR diffuser, to determine if there's much in terms of carbon build-up (on a non-deleted truck). I've seen a pile of videos from the eco-diesel where the diffuser gets so bunged up with carbon, that chunks falling off into your intake becomes a concern.

I know that these trucks have an air/oil separator off the PCV valve which should help minimize this problem significantly, however i'm just wondering if anyone has taken a look-see inside. As far as I can tell no one has really had a reason to open them up yet, which to me is a good sign!
 

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@Laytunes - been wondering the same thing as I have seen similar videos & pics -- I don't think there is any EGR design that can prevent this from happening... I guess the EGR By-Pass Recall v2.0 (20E04) will give us all an opportunity to see how good/bad things are "coked" up in the last ~18 months (my 18E02 was performance first week of Feb 2019)

Given the lack of a rental car or loaner again for 20E04, I will be spending the entire time at the dealer while 20E04 will be performed. I have a pretty good relationship with my Service Manager and lead diesel tech, so I will ask if I can get some pics of the engine ports on the engine side with the EGR By-Pass Valve removed, in addition to the side-by-side "old" vs "new" EGR By-Pass Valve assembly. I'll ask about the EGR Diffuser also but if that involves any additional labor beyond what 20E04 calls for, they may not comply. I'll post on the pics EGR By-Pass Recall v2.0 (20E04) thread with HTML links here to the pics here

Like I mentioned in the EGR By-Pass Recall v2.0 (20E04) thread, those affected will get a free EGR By-Pass Valve cleaning by the sheer fact the entire assembly will be replaced, but we hopefully won't be subjected to future recalls. This does lead to a long-term ownership question on how do we keep these engines "clean" and free of carbon build up? I've done some cursory research to find a plethora of after-market products that claim they can "clean" EGR paths without disassembling anything = you spray the product into the intake and somehow (by magic?) all the soot is removed, but there is only one path for the soot deposits to be removed = through standard engine combustion cycle.

I also tripped over a couple a wacko guys in the UK that use a "Carbon Engine Cleaning HHO" machine that somehow splits Hydrogen from de-ionized water and some chemical via electrolysis and the carbon is broken down into hydrocarbons by the OxyHydrogen gas = no idea if this actually works or if this is a bit of witch doctoring. Quick google search doesn't show anyone in the US selling these machines or offering this service, so not sure what to make of all off this HHO "Black Magic" I would think if such a machine actually worked, there would be one of these "green machines" is every diesel shop across the US.

Edit: I did find one (1) US company in IL providing mobile HHO cleaning service:

HHO Carbon Cleaning Systems

I do believe this is a longer-term ownership issue that we will all eventually need address, so you ask a good question and would like some feedback from prior SuperDuty owners on what they did...
 

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I purchased my 2018 in Dec 2018, had the initial EGR Recall (18E02) done in May 2019....Here is what the inside of the original EGR looked like after about 6 months of standard driving about 10,000 miles, with some but not much towing under 5,000 lbs. I had them take it to verify both bolts were still present rather than somewhere in the motor. Will do the same with 20E04 to ensure the washer is still in place (though from what I read if it failed the whole flap would fail and throw a CEL). Will post the photo when I have it done.
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