Disco 3 (LR3) Clean out your EGRs.

An issue i see quite often is the EGR valves on the 2.7 TD is EGR error codes and the inability to rev over 3000rpm.

Many if not all "myself included" just chuck on a new set of EGR valves and be done with it, that is a rather expensive ordeal considering what i'm going to show you costs around £10

Put yer D3 into "natural habital mode"




Remove the EGR to intake/exhaust pipe which is secured by torx fasteners, on the inlet side they're a ballache because of access issues, the bolts on the exhaust mani are 8mm standard..

Once removed, you can see the reason behind why so many are blanked off..


full of shyte, very common on a valve that has been sitting open for a prolonged period, also happens regardless etc etc

The fix for sticky or "seized" EGR valves is quite simple.

The EGR has an electric motor that opens/closes it, the fix involves removing this motor.
#1 Remove the very large grey power cable
#2 remove the 3 reverse torx E8 screws, the lower one is a right ache, if you're human and have "hands" I found it a pain, in my case I had to raise the car and stuff my hand between the chassis and body, just to remove the screw!!



EGR you can see here, complete with the Grey connector..

I find that 90% of all motors are perfectly fine and it is the valves at fault, usually seized from carbon build up..

The inner valve you can just about see, that is what seizes off

#1 you could stuff the mani with cloths but not really necessary for this stuff im going to mention..
#2 Use brake clean "non chlorinated" and cover/spray the valve, use a strong one, i find the STP brand do the best BC
#3 Once it is doused you could clean the valve out with a brass brush.
#4 Give it a squirt of penetrating oil and leave it while you check the motor..

#5 the motor itself should be free and moving smoothly, give it a squirt of contact cleaner anyway...

#6 give the EGR body a smack with a brass hammer, if it is stiff get a screwdriver and tap the valve inside, it should/will spring shut..

#7 spray more penetrating oil..

#8 Re-attach the motor and secure it, i used 2 out of the three bolts as the third one on the bottom i couldn't get in!!
it'll be fine with 2, trust me

stick the pipes back on and start her up.
make sure you clear the codes, and take it out for a good hoof to burn off any excess crap..

In my case it was Job done

2006 2.7 GS.


Henry_b's rambling. LOL

Hi

if u don’t mind me adding , don’t forget to clean the MAP sensor

silicone grease for the O rings

pre 2007 can be blanked without having a EGR software patch

Few pics of mine , I blanked mine , left pipes in situ, removed butterfly valve inside throttle body but of course egrs can’t be blanked if a DPF is fitted

EGR faults are now a big issue on the trucks, there isnt a day that goes past without one being in for repair.

Whoever invented these sht1e factorys?

Stanleysteamer said:

Whoever invented these sht1e factorys?

Click to expand...

hi

must admit runs nicer since I’ve cleaned everything out and blanked them, was a challenge getting the large Y piece throttle body back in without breaking it, found using some plumbers silicone grease worked a treat on the O rings

lynall said:

EGR faults are now a big issue on the trucks, there isnt a day that goes past without one being in for repair.

Click to expand...

Indeed and seen a good few on the D3 forum where they’ve been well choked up, inc the Map sensor

made the world of difference with that Map sensor clean, particularly going up hills

Also wouldn’t like to change an EGR , seeing there tucked down the side of the engine , inc removing the water cooling pipes

Stanleysteamer said:

Whoever invented these sht1e factorys?

Click to expand...

It is all about emissions, nowadays the engine is no longer king, the after treatment system is, and it governs the whole power delivery.
Some of the stuff is a nightmare, exhaust manifold gaskets on a 13 litre daf 1 hour for all 6, egr model 8 hours!

Parts prices are also nuts, daf 300 bhp engine turbo 1.1k, daf 300bhp engine turbo euro6 spec ie egr 4.3k!

lynall said:

It is all about emissions, nowadays the engine is no longer king, the after treatment system is, and it governs the whole power delivery.
Some of the stuff is a nightmare, exhaust manifold gaskets on a 13 litre daf 1 hour for all 6, egr model 8 hours!

Parts prices are also nuts, daf 300 bhp engine turbo 1.1k, daf 300bhp engine turbo euro6 spec ie egr 4.3k!

Click to expand...

What concerns me is that it should be obvious that pumping exhaust with dirt in it is not going to do any engine any good, after all, what is an air filter for, if you then stick oily muck back in? One LR mechanic I know talked about taking inlet manifolds off 300tdis and finding the inlet being so mucky it was down to less than 1cm diameter. Don't recall "Clean EGR valve and inlet manifold" being part of a service. Is it? If so, it must get missed off a lot!