recently a friends Mazda 6 ts 2.0 diesel 2005 has started reporting a low boost condition fault. I have identified the issue as being the egr stuck open during boost as the issue. I removed some of the piping to the EGR and left it to soak in carb cleaner which has removed some of the crud. However the build up is quite bad. The pipe is metal and about 20mm in diameter but is about 3/4s restricted by crud. I haven't yet removed the EGR itself or the intake manifold but i'm betting its just as bad. Any ideas short of throwing the lot away?
In order to clean it, just remove it
This is a messy job.
You don't want any of that carbonized waste going into the motor or all over yourself.
If you get an automotive parts dip, you can remove the EGR and place it in a basket and let it soak.
I use this for carburetors to EGR's. It will eat aluminum if you leave it in too long so check it periodically while it's soaking.
This is the cleanest and quickest method you can do. Before you put in the basket, if you must, you can pick away at the big chunks with an oil pick to help get it started. You will find quickly that this is an extremely messy job and you may want to forgo the manual picking and just allow it to soak in the parts dip.