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j,moore
Member Since: 26 Nov 2007
Location: out on the piste, or the piss
Posts: 138
  
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| egr and butterfly valve pics |
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as i said here are some pics to show i did my conversion,
take off the covers and ducting, be sure to cover the air intakes to prevent anything entering,
remove the air intake duct shown,
remove the actuator, the round thing whith the wires on the end, this is very fiddly and i ended up removing the black bracket undernieth and the long bolt in the top,then i didnt put the back bottom stud back in the actuator, three is enough i think, make sure you replace the black bracket though,
carefuly remove the butterfly rod as shown,
remove the butterfly valve,
then reassemble the rod as removed whith out the valve,
then put the whole assembly back together, dont forget to conect the actuator inkage to the rod,
this is a basic run down of what to do to remove this valve, just be verry careful not to let anything get into any of the air intake ducts because if you do and then you start the engine it will f  k it up big style. also can i please state i cannot be held responsible for any damage caused from any advice given, thanks anyway. 
Last edited by j,moore on Wed Mar 19 2008 11:09pm. Edited 2 times in total
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 Wed Mar 19 2008 7:31pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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So, errr..... what benefit does removing the butterfly valve give? the EGR pipes behind the valve appear to still be connected and not blanked off so will still pump exhaust gases into the inlet manifold - won't they? TorqTune
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| Wed Mar 19 2008 7:35pm |
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j,moore
Member Since: 26 Nov 2007
Location: out on the piste, or the piss
Posts: 138
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now to blank off the egrs,
thease are the pipes, use a suitable tool to remove the top clips,
remove the two studs on the flange of the stainless pipe, do not loose the gasket,
remove the pipe and then reasemble whith a suitable blanking plate maide out of stainless plate, and reassemble whith the plate ontop of the gasket. you could put a gasket on the top and bottom if you prefered,
this is a picture of the pesky egr valve,
as re assembled,
and do the same procedure for the other side, there is alot less room so be carefull and dont loose your cool,
and then dont forget to put the clips back on the pipes and reclip any wires and put the whole thing back together and thats about it. please be carefull and as said above please dont hold me responsible for any damage. my disco has done over 17000miles cince this was done and i have had no problems so i dont see why this wont work for all other cars. i have more pics on my gallery to help so good luck.
regards jim.
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| Wed Mar 19 2008 7:51pm |
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j,moore
Member Since: 26 Nov 2007
Location: out on the piste, or the piss
Posts: 138
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sorry 10forcash, you beat my second post, im not as fast at typing sorry, 
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| Wed Mar 19 2008 7:55pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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makes sense now! TorqTune
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| Wed Mar 19 2008 8:14pm |
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simon
Member Since: 11 Jan 2005
Location: Sitting pensively in front of the mouse trap looking at the cheese
Posts: 17981
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So can someone explain why you would want to do this ?
Surely blanking off the EGR valves is not normal else LR would have done it.
Confused of Shropshire.
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| Wed Mar 19 2008 9:24pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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EGR's are there purely for emission control, they have zero benefit to engine performance, longevity or fuel efficiency....
In the light of the announced punitive taxes I suggest we all blank off the EGR's (although i'm not sure of the benefit of removal of the butterfly valve...) so that we can be sure of getting maximum value from the fuel we're paying (and being double taxed) for!
Generally, EGR's are only active (open) once the throttle has been released to 'recycle' some of the unburnt gases although to comply with EU4 regs, the EGR's are more active in the mid to low throttle range, blanking them off ensures that only fresh air and fuel enters the cylinders TorqTune
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| Wed Mar 19 2008 9:32pm |
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simon
Member Since: 11 Jan 2005
Location: Sitting pensively in front of the mouse trap looking at the cheese
Posts: 17981
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Sorry...
So does it make the engine more efficient power wise or fuel consumption wise if you blank them off ?
If blanked then no recycling of unburnt gases is taking place.
Or does recycle not mean re-use in this case?
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| Wed Mar 19 2008 9:36pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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recycle means that the unburnt fuels get pumped back into the engine instead of out of the exhaust - great for the twot in the BM / Pious / repmobeel behind you, not so great for the D3's performance, 100% fresh air and fresh fuel will always give you better fuel economy and better performance than stale stuff of varying percentages
EGR's are also responsible for choking up the inlet manifold with carbon deposits, restricting the airflow and reducing performance still further.... TorqTune
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| Wed Mar 19 2008 9:42pm |
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simon
Member Since: 11 Jan 2005
Location: Sitting pensively in front of the mouse trap looking at the cheese
Posts: 17981
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Sounds good.
But does that not mean that your emissions testing during an MOT would go out of kilter up to the point of it failing ?
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| Wed Mar 19 2008 9:48pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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possibly - if you leave the blanking plate in there for the test  TorqTune
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| Wed Mar 19 2008 9:49pm |
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stapldm
Member Since: 11 Sep 2006
Location: Swine Town
Posts: 2065
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Although the EGR blanking instructions are brilliant I'm confused about removal of the butterfly plate; isn't this part of the engine braking mechanism? corruptissima re publica plurimae leges
Loosely, "The state with the most corruption has the most laws"
In it's first 9 years alone labour created over 3000 new offences (that's one a day)...corrupt? You decide...
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| Wed Mar 19 2008 9:52pm |
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Gareth
Site Moderator
Member Since: 07 Dec 2004
Location: Bramhall
Posts: 12903
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I think the point is that a normally functioning pair of EGR valves will make a negligible difference to engine performance at low throttle settings, and zero difference at higher throttle, because they are supposed to shut when you put your foot down.
When they malfunction, or become clogged, which appears to be happening to a fair few vehicles, then they are very detrimental to performance in general.
Blanking seems to be the cost effective way of fixing the fault if your car is out of warranty. Its been a regular modification on 300tdi D1's and I think TD5's
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| Wed Mar 19 2008 9:53pm |
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10forcash
Site Sponsor
Member Since: 09 Jun 2005
Location: Ubique
Posts: 16460
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stapldm wrote:Although the EGR blanking instructions are brilliant I'm confused about removal of the butterfly plate; isn't this part of the engine braking mechanism?
yes it is - especially on auto boxed versions, the butterfly also forces the engine to suck in exhaust gases when the throttle is closed
Gareth - 100% on the 300tdi & TD5 TorqTune
Vehicle maintenance, modifications, training and equipment
Driving adventures
Autologic Diagnostics equipped!
Tunisia Feb. 2010
Please use the email button to contact me rather than the PM button - Thanks!
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| Wed Mar 19 2008 9:57pm |
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