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I'm driving a 2017 Tata Hexa XT 4x4, and recently the EGR sensor warning came on at around 67,000 km. Is this a common issue with all Tata Hexas, or is it specific to certain vehicles? This cost me a huge amount to replace the new EGR and Turbocharger.
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The EGR sensor warning is not uncommon on the Tata Hexa, especially as the vehicle ages and accumulates mileage. The Hexa's 2.2-litre diesel engine is equipped with an EGR system to reduce emissions, and over time, carbon build-up can cause the EGR valve or sensor to malfunction. This is not unique to the Hexa; it is a known issue on many modern diesel engines, particularly those used predominantly in city conditions where the EGR system is more active, and regeneration cycles are less effective.
The need to replace both the EGR and turbocharger at 67,000 km is unfortunate but not unheard of. If the EGR valve becomes stuck or fails, it can lead to increased soot and carbon deposits, which can eventually affect the turbocharger's variable geometry vanes or actuator. This can trigger a cascade of warnings and, if not addressed promptly, lead to more expensive repairs.
The best way to minimise the risk is to ensure regular long highway runs, use good quality diesel, and follow the recommended service intervals. Periodic EGR cleaning can also help. Overall, this is not a design flaw specific to the Hexa but rather a maintenance-related issue that can affect any modern diesel car with an EGR system.
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Posted on: 24 Jul 2026
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