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Hi Roy,

EGR will definitely increase your soot loading on the engine oil but I have not heard about hydrochloric acid building up in an engine. Chlorine is not part of any lubrication make-up (not engines anyway) and the only way it could get in there is by external contamination.

A couple of questions:
  • Are you referring to acidity or specifically hydrochloric acid?
  • Is there a possible source of chlorine in the vicinity? (i. e. is the unit working in a chemical plant)
  • The EGR units are add-on, how about contacting the supplier and asking if these units are acid cleaned before dispatch to customers, there might be a residual chlorine deposit as a result of improper flushing techniques ...
  • Are these engines running hotter than usual, as this might accelerate oxidation and acid formation.
  • How does the rest of your used oil analysis on these units look?

    Have a terrific day.
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