EGR valve cleaning

The flex pipes before and after the DPF were clear. The DOC and DPF both looked pretty clean, but they're getting the ultrasonic treatment and I'll pick them up Monday. I ended up breaking two bolts on the stairs due to corrosion, and two bolts on the smaller V band. While removing the delta P sensor from the tube, one of the plastic barbs snapped. So if the problem gets fixed, I won't really be able to tell if it was due to the cleaning or a bad sensor.

 

Put the cleaned DPF back in yesterday and did a test drive today. The soot level didn't even budge, it stayed empty. The guys who cleaned it said it had a fair amount of ash, but it wasn't even close to the worst that they've seen. I'm guessing the problem was with the DPF's Delta P sensor, or possibly the metal tube on the dirty side leading up to it.

 

$132.58 for the 2 EGR rubber hose kits on each end of the venturi tube
$225.39 for DPF Delta P sensor ($128) and two V clamps ($39x2)
$350.00 for the DPF/DOC cleaning at DPF Alternatives in Denver
I bought the 2 large gaskets and 4 smaller ones a long time ago, so I don't remember the price. I would say the total would be around $800 with gaskets, carb cleaner, etc. You could probably even save like $100 not buying parts from the dealership.

I spent maybe 2 hours removing, cleaning, and reinstalling the venturi tube.
Removing the DPF took maybe 2 hours
Cleaning DPF/DOC was a 24 hour turnaround
Reinstalling DPF was like 4 hours. I broke the bolts they welded on the stair bracket, so I had to fabricate new mounts

If everything went smooth, it would probably take little more than a day with most of it waiting on the filter to get done. As for the flex pipe, I figured out that you can press it together like an accordion so it will collapse enough to give you the room for it to fit without damaging the gaskets. I did get a code today (SPN 3216 FMI 13) for NOx sensor not calibrated, so I used the OTR performance tool to reset everything and will keep an eye on it.

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Cleaning the venturi tube fixed the turbo surging. I think replacing the Delta P sensor and cleaning out the metal tubes on the DPF fixed the soot problem. The DPF/DOC needed to get cleaned anyway, but I'm not sure if it was causing any issues. I never got around to cleaning the 7th injector or EGR valve.