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egr and butterfly valve pics
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robsmith
Joined: 02 Sep 2007
Location: Staffordshire
Posts: 406
 
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My feeling is they either do ro they don't and if they don't then the screw comes into its own rahter than breaking anything that you don't want to.
One thing that amazed me is the amount of plastic used on the engine, it looks as if much of the inlet manifold is plastic of some sort or another, along with many of the stuff screwed onto it.
In a few miles I'll give the bolts a quick tweek just to make sure (again habbit form working on old cars). Rob Smith
Silver rools OK
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 Fri May 09 2008 7:15pm |
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Ken
Joined: 20 Feb 2006
Location: Here & There
Posts: 3838
 
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Cant post any pics mine never showed up ahh welll Each day that ends brings me one day closer to my demise
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| Fri May 09 2008 9:21pm |
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robsmith
Joined: 02 Sep 2007
Location: Staffordshire
Posts: 406
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First driving impression:
No hesitation at the end of the road, always a good test as its a left turn onto a busy uphill section.
Second:
Ease off a bit or I'll thrutch that Corsa one 
Third:
Fuel consumption around town looks to be a bit better Rob Smith
Silver rools OK
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| Sun May 11 2008 7:30am |
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stapldm
Joined: 11 Sep 2006
Location: In a queue for diesel
Posts: 829
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I finally got some Me time today and started to put in my EGR blanking plates. Sadly rain stopped play before I got the butterfly valve out  but both plates are successfully installed.
Saw a couple of grim sights though (other than my reflection in my spanners).
First check out how corroded my EGR bolts were; one of them was down 25% of material just underneath the bolt head  TLO, I'll be talking with you again very soon, but did anyone else find their bolts like this?
Also I decided to take look inside my inlet manifold, so popped out the EGR pipe. OMG  In many ways I'm pretty sorry I did. I removed about 2 teaspoons of gunk from inside the manifold at the EGR port access, and there was more stuck to the pipe along with between 2 and 3mm thick carbon build-up in the pipe itself
So, will I harm anything by using Carb cleaner in situ? Or should I strip it all to clean it off the vehicle? I'd hate to think what a lump of this Tarmac would do to a valve if it headed down that way  Give a man a fire and he's warm for the day. But set fire to him and he's warm for the rest of his life.
Terry Pratchett, Discworld
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| Mon Jul 07 2008 9:35pm |
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robsmith
Joined: 02 Sep 2007
Location: Staffordshire
Posts: 406
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Ouch 
That looks quite nasty, and if the rest of the manifold is in a similar state.....
Not knowing what the manifold looks like inside I'd go for the take it off solution as the last thing you want to do is start a diesel with a load of nice flamiable fuel sitting in a dark corner of the maniflod for the air to pick up and throw into the combustion chamber - don't ask how I know - the results are "spectacular", then "expensive". Rob Smith
Silver rools OK
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| Tue Jul 08 2008 8:51am |
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al cope
Joined: 08 Nov 2005
Location: Oldbury, WM
Posts: 1568
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what sort of mileage on yours? I think I was at about 48k when I did mine, and both the bolts and that tube were in no where near that sort of state. Bolts had a bit of marking, but not that sort of corrosion, and pipes were black, but not cruddy like that.
Al TDV6 S - Tonga with Ebony
(and 19" RRS alloys, satnav & DVD)
Vote for Global Warming - Cambridge on Sea sounds good to me, no more using the M5 to get to the seaside
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| Tue Jul 08 2008 10:03am |
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stapldm
Joined: 11 Sep 2006
Location: In a queue for diesel
Posts: 829
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Thanks guys,
I've done just 18,000 miles and 18ish months. There's also a film of oil in the air intake duct, I guess this is turbo seepage.
Today I have a collection of faults too:
HDC off, limited gears (AKA stuck in one you're in when it errors), Suspension lowering, DSC warning light on, Suspension warning light on, Special programs unavailable, EPB failure (twice!) etc etc.
Nursed it to the dealers, who checked it over and said it was a cascade fault caused by two initial faults : EGR flow too high and Mass air flow too high...and as both can't occur at the same time it threw a fit. So why the  didn't it report an engine problem? With all those errors I assumed it was a loose plug in the harness.
I have no clue as yet as to how much THAT 2+ hours investigation is going to cost me I suspect it'll be more than I'm saving (MPG per the trip computer is up 4MPG) from fitting the blanking plates.
Looks like I'm removing it all and seeing what state everything is in when it's back to factory spec....
Sorry, need to again.
Just as a matter of interest; Anyone know what that sensor is in the air intake section between the intercooler hose coming up and the butterfly valve? It's covered in oil; was wondering more in hope than in anger if that could be causing the errors? Give a man a fire and he's warm for the day. But set fire to him and he's warm for the rest of his life.
Terry Pratchett, Discworld
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| Tue Jul 08 2008 5:48pm |
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simon
Joined: 11 Jan 2005
Location: Do you really need to know ?
Posts: 13905
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stapldm wrote:
Nursed it to the dealers, who checked it over and said it was a cascade fault caused by two initial faults : EGR flow too high and Mass air flow too high...and as both can't occur at the same time it threw a fit
This confuses me somewhat too. How can a fault with EGR flow etc cause errors around the whole vehicle ?
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| Tue Jul 08 2008 6:00pm |
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stapldm
Joined: 11 Sep 2006
Location: In a queue for diesel
Posts: 829
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I got the impression they thought this was normal. Something along the lines of "If the CAN Bus reports something happening that can't be true (plausability check) then everything that relies on the CANBus shuts down."
I said it was pretty poor that when the system sees an engine fault, it leaves the engine running normally (didn't get a reduced power message) yet shut down all the safety systems 
BTW, in spite of two warnings that the EPB had failed, it still worked fine. If you get two warnings about something, do they cancel out? Give a man a fire and he's warm for the day. But set fire to him and he's warm for the rest of his life.
Terry Pratchett, Discworld
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| Tue Jul 08 2008 6:05pm |
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Hobgoblin
Joined: 15 Nov 2007
Location: Shropshire
Posts: 429
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stapldm, when I fitted the blanking plates I immediately got the symptoms you have had, HDC off, limited gears (AKA stuck in one you're in when it errors), Suspension lowering, DSC warning light on, Suspension warning light on, Special programs unavailable, EPB failure.
Removed the plates, no more problem, since, I have removed the butterfly, this on its own has a possitive effect, I did this before going to Tunis and the car ran like a dream, so I have come to the conclusion that mine didn't like the blanking plates. I'm not as good as I once was........but I'm as good once as I ever was.
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| Tue Jul 08 2008 6:08pm |
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London Lad
Joined: 27 May 2008
Location: Suffolk
Posts: 28
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simon wrote:snip
This confuses me somewhat too. How can a fault with EGR flow etc cause errors around the whole vehicle ?
I had a MB SL and from time to time it would freak out and go into limp home mode, disable the electronically controlled breaks, report transmission faults, engine faults etc etc.
After much trial and error diagnosis it turned out to be the parking sensor control box intermittently outputting junk data that was interpreted by the CAN BUS as a multitude of other faults.
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| Tue Jul 08 2008 6:22pm |
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chesters
Joined: 03 Oct 2005
Location: The Toon
Posts: 418
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I was going to do this mod today but I am now having second thoughts, after reading the last couple of threads.
I need some positive response, as my Disco is running great and I don't want to break it.
Who has done this mod and had no problems, my Disco is a Dec 2005 MY06 with 20k miles on the clock. Arctic Frost Discovery 3 TDV6 SE, Active Rear Diff, Adaptive Head Lights, Tow Pack, Ebony Leather, Roof Rails, Mantec Guard. Tasmod Stainless Sill plates. Grabber AT2's. Home made mud flaps. Side Steps back on until the next time.
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| Tue Jul 08 2008 8:18pm |
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kontos
Joined: 10 Apr 2007
Location: ATHENS
Posts: 6
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I have done this mod about 5000 khm before .
no problem at all and
Fuel consumption around town looks to be a better 4 mpg
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| Tue Jul 08 2008 8:37pm |
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stapldm
Joined: 11 Sep 2006
Location: In a queue for diesel
Posts: 829
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Thanks Hobgoblin, that looks like what I'll have to do. I've been thinking about one of the errors - EGR flow too high. OK so it's dead wrong, as there's no flow at all; but how does it know it's too high? Is it possible that 2007 onwards engines have pressure sensors that can detect EGR flow by the pressure difference across the EGR valve? If so, maybe these blanking plates are not an option on later models
London Lad, thanks for that. I can see why a malfunctioning CAN Bus node could cause garbage on the bus and that could (should) cause everything to shut-down; it would be dangerous to continue in case a random message actually meant something to a node. In my case though there was simply a contradiction between two engine sensors; neither of which affected any of the drive train or safety systems. If the Bus is clean, why does it need to disregard the data on it? I'm with Simon here, it simply doesn't make sense.
Al, thinking about it, the gaskets at the EGR manifold have a cut-out in them. My EGR top pipes also have a chamfer in them, and logically these should align to ensure the gasket is the right way around. If this is the case, then mine were definitely installed upside down, so the damaged screws could be from a small amount of gas getting past.
I'm off for another Give a man a fire and he's warm for the day. But set fire to him and he's warm for the rest of his life.
Terry Pratchett, Discworld
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| Tue Jul 08 2008 8:49pm |
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stapldm
Joined: 11 Sep 2006
Location: In a queue for diesel
Posts: 829
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kontos wrote:Fuel consumption around town looks to be a better 4 mpg
Agreed! I found exactly the same, and also noted that the engine was more responsive and quieter too.
Good question Chesters; it'd be good to know if anyone with MY2007 or later has succeeded with this mod. There appear to be many MY2006 or earlier that have not had any issues at all (in which case you may be fine). Give a man a fire and he's warm for the day. But set fire to him and he's warm for the rest of his life.
Terry Pratchett, Discworld
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| Tue Jul 08 2008 8:54pm |
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