The Complete Guide to EGT Sensors: Symptoms of Failure, P0544 Codes & Replacement Cost

Modern engines, especially diesel ones, are packed with sensors designed to lower emissions and protect the engine. One of the most critical—yet often overlooked—components is the Exhaust Gas Temperature (EGT) Sensor.

If you drive a Renault, Dacia, Nissan (1.5 dCi), or a VW/Audi, you might have encountered the dreaded Check Engine Light coupled with a "Check Injection System" or "Anti-Pollution" warning.

This guide serves as your comprehensive resource for understanding EGT sensors. We will cover why they fail, how to diagnose common error codes like P0544, and link you to specific repair guides for your vehicle.

What is an EGT Sensor and Why is it Important?

The Exhaust Gas Temperature sensor does exactly what its name suggests: it monitors the temperature of the exhaust gas. But why does the ECU (Engine Control Unit) need to know this?

1. Protecting the Turbocharger: If the exhaust gets too hot, it can melt the turbine blades. The EGT sensor warns the ECU to reduce power if temps get critical.

2. DPF Regeneration (Crucial for Diesels): This is the #1 reason for failure on cars like the Dacia Duster or Kia Ceed. The ECU needs precise temperature readings to burn off soot in the Diesel Particulate Filter (DPF). If the sensor fails, DPF regeneration stops, leading to a clogged filter and a very expensive repair bill.

5 Common Symptoms of a Bad EGT Sensor

How do you know if your sensor is failing? Look for these signs:

1. Check Engine Light (CEL)

The most obvious sign. The ECU detects an implausible reading (like -40°C or +900°C instantly) and triggers a code.

2. DPF Warning Light / Failure to Regenerate

If the EGT sensor is dead, the car won't know if the exhaust is hot enough to burn soot. It will disable the cleaning cycle (Regen), causing your DPF light to turn on.

3. Limp Mode (Loss of Power)

To protect the engine from overheating, the ECU may cut the turbo boost. Your car will feel sluggish and struggle to accelerate above 2000 RPM.

4. Increased Fuel Consumption

Without accurate temperature data, the ECU may inject more fuel than necessary to cool the combustion chamber, wasting diesel.

5. Rough Idle or Stalling

While less common, extreme sensor readings can mess up the air-fuel mixture calculation, causing the engine to run roughly.

Decoding the Error Codes: P0544, P0546, P2033

When you plug in an OBD-II scanner, you will likely see one of these codes.

P0544 - Exhaust Gas Temperature Sensor Circuit - Bank 1 Sensor 1

This is the most common code we see, especially on Renault/Dacia 1.5 dCi engines. It usually means the sensor circuit is "open" (broken wire or dead sensor).

• Do you own a Dacia Duster or Renault? Check our specific repair guide:
  [👉 How to Fix P0544 Code on Dacia Duster 1.5 dCi: Replace EGT Sensor 8200921749]

P0546 / P2033 - Sensor Circuit High

This indicates a short circuit to voltage or a sensor that has failed internally, reading a constantly high temperature.

P2031 / P2032

These often refer to the Sensor 2 (located after the Catalytic Converter or DPF).

• Confused about Sensor locations? Read our guide on Upstream vs. Downstream:
  [👉 Upstream vs. Downstream Sensors Explained]

Why Do EGT Sensors Fail?

EGT sensors live in an incredibly hostile environment.

• Extreme Heat: They sit directly in the exhaust stream, enduring temperatures up to 900°C (1650°F).

• Vibration: Constant engine vibration can break the delicate internal wires.

• Thermal Shock: Going from freezing cold to blazing hot in minutes causes the metal casing to expand and contract, eventually cracking the internal element.

Spotlight on Part #8200921749
If you drive a Nissan Qashqai, Juke, NV200, or a Dacia Duster/Logan, this specific part number is notorious for failing. We have seen thousands of these fail due to wire fatigue near the connector.

[👉 Shop the High-Quality Replacement for 8200921749 Here]

Replacement Cost: Dealer vs. DIY

Replacing an EGT sensor is usually not difficult, but it can be expensive if you go to a dealer.

• Dealership Price: Expect to pay $150 - 

  $250\ast \ast forthesensor,plus\ast \ast$

  150 for labor/diagnostics. Total: $300+.

   

• DIY Price: You can buy an OEM-quality aftermarket sensor from Automotive Leader for $40 - $70 and install it yourself.

Tools Needed:

• A 14mm or 17mm Line Wrench (Flare Nut Wrench) is best to avoid stripping the sensor nut.

• Penetrating Oil (WD-40) – Essential, as these sensors are often rusted in.

DIY Step-by-Step Overview

1. Locate the sensor: Consult your service manual. Sensor 1 is usually on the manifold or before the turbo.

2. Soak it: Spray penetrating oil on the threads and let it sit for 15 minutes.

3. Unplug: Disconnect the electrical connector.

4. Unscrew: Use your wrench to carefully loosen the sensor.

5. Install: Screw in the new sensor (apply anti-seize to threads if not pre-applied) and plug it in.

6. Clear Codes: Use your scanner to clear the P0544 code.

• For a detailed walkthrough on replacing the Renault/Nissan sensor, read this guide:
  [👉 DIY Guide: Replacing EGT Sensor 8200921749]

Conclusion

Don't ignore an EGT sensor fault. While the part itself is small, the damage it can cause to your DPF and Turbo is massive.

At Automotive Leader, we specialize in high-temperature sensors that meet or exceed OEM specifications. Whether you need the notorious 8200921749 for your Dacia or a sensor for your VW, we have you covered with fast shipping and warranty.

Ready to clear that code?

[👉 Browse Our Full Catalog of EGT Sensors]