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egr and butterfly valve pics
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SKYWRITER
Joined: 02 Jul 2007
Location: MERSEYSIDE
Posts: 62
 
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i recently blocked off my egr valve on a 12 month old fiat panda multi-jet the difference in performance was brilliant , and the increase in turbo boost pressure was very noticeable, when my disco comes out of warranty there being gaged as well AUDI S4 4.2 V8 panda multijet, vespa et4, eccles opal,
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 Fri Mar 28 2008 12:41am |
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Discoeast
Joined: 19 Feb 2008
Location: Boksburg
Posts: 121
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I have a MY07 and read with interest on the EGR conversion, to me it just makes sence to convert.
So out with the tool box, plasma cutter, drilling machine, my son and let the games begin.
As with over eager converters, we managed to drop both the gaskets on removing the EGR piping 
With some confined fishing skills, choice  words, they were retrieved.
A few hints for would be converters.
1) Loosen the EGR pipe bolts, place hand under flange mount, remove pipe sections with bolts in bolt holes.
Fishing for droped spares in a Disco 3 engine bay  and catch the gaskets.
2)There is enough movement in the intake "Y" piece on the "O"rings to lift the butter fly assembly up to get access to the bottom screws of the butter fly accuator, be carefull not to lift too high.
3) Apply some sealer to the blank plate,gasket,mounting flange so that it will not slide off when positioned for re-fitting. I used a Wurth product called DP 300.
I used a 1.6 mm stainless for my blanks and had no fitting problems.
Hope this will help other converts. Tdi 130 conversion-full house, Disco 2, Freelander, D3 bullbar-spots-roof rack with spots-ladder-long range tank-swing out spare wheel carrier- upgraded tow bar-dash console-internal water tank-duel awnings-drawer system & T T.
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| Sat Mar 29 2008 1:27pm |
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ridgeback_moor
Joined: 11 Mar 2008
Location: Devon
Posts: 410
 
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A thin smear of blue hylomar works well to hold the bits together (ie the flange, blank and gasket) for re-assembly as well - it's rated to 250 deg C, but from what I can see the temperature doesn't get anywhere near that high at the blank once fitted. As discoeast said, the gasket easily drops off the flange once it's removed from the EGR so well worth having some kind of plan to catch it before removing the bolts - believe me it saves a lot of time later. I had to remove the sump plate (10 tight bolts!) just to get 1 screw out D3 TDV6 S 2005 - TorqTune, Privacy Glass, Remote FBH, 19" HSE Alloys, Boot liner, retrofit F&R PDC
Defender 90 Truck Cab TD5 2003 - Ifor Williams back, alloys (SWMBO's toy - well, one of them  )
Toyota Yaris 2008 (SWMBO's company shopping trolley)
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| Sat Mar 29 2008 2:19pm |
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AndrewW
Joined: 06 Aug 2007
Location: Saddleworth
Posts: 1219
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Thanks for the info., esp 1.6mm = GOOD 
Any-one else with a pocket, AA-powered plasma cutter??  
A 06 TDV6 SE Tonga Green
Mantec Plate (with three "dings"), BCB rope, Hidden winch (hidden in garage...), Webasto timer (in box), TorqTuned ((tee hee)²), Origin b2 (in case), Traffic master jam warner (in expectation), FT8800, Motorola GM360, INTEK H-520+ (in a tangle)
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| Tue Apr 01 2008 6:00pm |
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Rob Bruce
Joined: 18 Jun 2006
Location: Canberra
Posts: 512
 
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Andrew,
Got a plasma cutter, but its in Oz But seriously it is the easiest way to cut the blanking plates, a tip though, make a templete the apropriate size either larger or smaller to follow around, ie. smaller or larger by the distance from the centre of the plaz. tip to the outside and that will guarentee a neet accurate job.
Good luck
Rob
PS. Think that makes sence eneyway someone with a plaz. cutter will know what I am talking about.
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| Wed Apr 02 2008 8:31am |
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ridgeback_moor
Joined: 11 Mar 2008
Location: Devon
Posts: 410
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AndrewW - do you need someone with a plasma cutter? My mate's got a crash repair business so he has one, as well as a few engineering companies round here where I work. If you need me to ask, let me know. D3 TDV6 S 2005 - TorqTune, Privacy Glass, Remote FBH, 19" HSE Alloys, Boot liner, retrofit F&R PDC
Defender 90 Truck Cab TD5 2003 - Ifor Williams back, alloys (SWMBO's toy - well, one of them )
Toyota Yaris 2008 (SWMBO's company shopping trolley)
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| Wed Apr 02 2008 10:29am |
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AndrewW
Joined: 06 Aug 2007
Location: Saddleworth
Posts: 1219
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Rob,
Thanks for the info. I just love toys  , but I can't justify a plasma cutter  . Besides I value my fingers!
We are looking into the EGR plate group-buy supplying laser-cut plates, so I have even less justification.
Andy - thanks for the offer. Not needed at present, but I'll take a rain-check as they say. Not that we are close neighbours (except by Oz standards ), but the D3 logistics division is legendary .
Everyone - the price is right!
Final pricing will be posted on the group buy thread when I have checked postage / package costs
Andy 06 TDV6 SE Tonga Green
Mantec Plate (with three "dings"), BCB rope, Hidden winch (hidden in garage...), Webasto timer (in box), TorqTuned ((tee hee)²), Origin b2 (in case), Traffic master jam warner (in expectation), FT8800, Motorola GM360, INTEK H-520+ (in a tangle)
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| Wed Apr 02 2008 12:29pm |
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simonsi
Joined: 14 Oct 2007
Location: Leicester
Posts: 684
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Well I now have the EGRs blanked in addition to the butterfly valve plate removed and I have to say I find it very hard to even provoke any pickup hesitation, any that remains is, I think and feel, down to the gearbox making a decision to change down rather than then engine having no go.
Around town mpg looks better by 1-2mpg minimum but no obvious effect on motorway cruising mpg - bear in mind that AFAIK my EGRs were not failing beforehand.
I wouldn't worry about the material to make the plates of too much, the EGR valve blocks seem to be aluminium. Cheers
Simon
TDV6 S Auto - Zambezi Silver - JE Tune - RRS 19" - Sidesteps - Roof Rails
Body Side Strips - Xenons - Bright Pack - Cold Pack - Premium Stereo
Alpine Roof - Towpack - Alpine Touchscreen Satnav - Veba Rear DVD changer
Alpine Roof Monitor - Webasto FBH Timer - Awesome Brembo Frt & S/C Rr Brakes
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| Wed Apr 02 2008 12:47pm |
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ridgeback_moor
Joined: 11 Mar 2008
Location: Devon
Posts: 410
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I thought the block was Ali too, but after a closer look I think it's stainless. Could be wrong. I'm still convinced the temperature experienced by the EGR valve is now quite low as there is no flowing hot exhaust gas - the next project is the attach a thermocouple and go for a blast. It makes sense to make the blanks out of stainless though to avoid any dissimilar metal problems. My current ones are mild though, but I'll whip them out in a few months to see how they are holding up. D3 TDV6 S 2005 - TorqTune, Privacy Glass, Remote FBH, 19" HSE Alloys, Boot liner, retrofit F&R PDC
Defender 90 Truck Cab TD5 2003 - Ifor Williams back, alloys (SWMBO's toy - well, one of them )
Toyota Yaris 2008 (SWMBO's company shopping trolley)
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| Wed Apr 02 2008 2:07pm |
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simonsi
Joined: 14 Oct 2007
Location: Leicester
Posts: 684
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ridgeback_moor wrote:It makes sense to make the blanks out of stainless though to avoid any dissimilar metal problems.
But if the EGR valve block IS ally then you'll still need gaskets both sides of the stainless plate to be sure.
Not sure what the best material would be if the block is ally and the EGR pipes are (electro-plated steel????)?? Presume any galvanic corrosion is prevented by gaskets seperating the metals whatever they are. Cheers
Simon
TDV6 S Auto - Zambezi Silver - JE Tune - RRS 19" - Sidesteps - Roof Rails
Body Side Strips - Xenons - Bright Pack - Cold Pack - Premium Stereo
Alpine Roof - Towpack - Alpine Touchscreen Satnav - Veba Rear DVD changer
Alpine Roof Monitor - Webasto FBH Timer - Awesome Brembo Frt & S/C Rr Brakes
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| Wed Apr 02 2008 2:14pm |
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simonsi
Joined: 14 Oct 2007
Location: Leicester
Posts: 684
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Further 500 miles covered and two results:
Firstly I have had the highest ever for me combination of range remaining and trip distance covered at 580 miles (mines auto remember).
Also had her checked and no fault codes logged.
Performance remains consistant and hesitation-free Top tip Jim!!! Cheers
Simon
TDV6 S Auto - Zambezi Silver - JE Tune - RRS 19" - Sidesteps - Roof Rails
Body Side Strips - Xenons - Bright Pack - Cold Pack - Premium Stereo
Alpine Roof - Towpack - Alpine Touchscreen Satnav - Veba Rear DVD changer
Alpine Roof Monitor - Webasto FBH Timer - Awesome Brembo Frt & S/C Rr Brakes
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| Thu Apr 03 2008 9:55pm |
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Andy4467
Joined: 25 Nov 2005
Location: Kent - England
Posts: 190
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I'm on the EGR waiting list ----- pah.!
Thanks for the info
I'll be modding mine this weekend whilst waiting for the " the parts are now in stock" phone call.
J.Moore - Simonsi  Some say the glass is half full. Others that it is half empty. I say 'Are you drinking that?"
Cairns Blue, Ebony Leather, SE
BMW 320d M sport
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| Thu Apr 03 2008 10:37pm |
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simonsi
Joined: 14 Oct 2007
Location: Leicester
Posts: 684
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 Cheers
Simon
TDV6 S Auto - Zambezi Silver - JE Tune - RRS 19" - Sidesteps - Roof Rails
Body Side Strips - Xenons - Bright Pack - Cold Pack - Premium Stereo
Alpine Roof - Towpack - Alpine Touchscreen Satnav - Veba Rear DVD changer
Alpine Roof Monitor - Webasto FBH Timer - Awesome Brembo Frt & S/C Rr Brakes
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| Thu Apr 03 2008 10:47pm |
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AndrewW
Joined: 06 Aug 2007
Location: Saddleworth
Posts: 1219
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Chaps - we are days away from the group buy on STAINLESS blanking plates.
There has been a huge bump in the road but we are still hopefully on course - if interested, please check out the EGR blanking plate Group Buy thread...
Andy 06 TDV6 SE Tonga Green
Mantec Plate (with three "dings"), BCB rope, Hidden winch (hidden in garage...), Webasto timer (in box), TorqTuned ((tee hee)²), Origin b2 (in case), Traffic master jam warner (in expectation), FT8800, Motorola GM360, INTEK H-520+ (in a tangle)
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| Thu Apr 03 2008 10:51pm |
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alinton
Joined: 06 Feb 2006
Location: Waterford, Ireland.
Posts: 75
 
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I just did the mod and it was easier than it looks.
A 'scew-driver' is a useful tool, to get at the screws that hold the actuator on. I removed the bolt that goes vertically through the inlet 'Y' pipe which allowed me to raise it up a bit to get to the bottom screws.
It also helps if you undo the unions where the EGR pipes connect to their inlets.
In fact, once I'd done this, I could see that the entire Y assembly would in fact remove completely, if you wanted to do the job on your kitchen table - the Y pipe just pulls out of the inlets.
Then I had a look, and those EGR inlets remove with a pair of screws each. The 'spouts' inside are only soft alloy, so I blocked them by squeezing them in a vice.
Therefore no blanking plates required and no need to delve further down to disconnect the EGR pipes at their flanges.
It was a little difficult to refit those union clips but not impossible.
All back together, job's a good 'un. Took about an hour all told.
I'll report performance results shortly...
Andy.
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| Sat Apr 05 2008 3:45pm |
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