Egr Blanking Mod

I've got my Synergy 2 and fitting it took me a bit of time. Setting 10, MAF on (fortunately I've installed Pierburgh from Eurocarparts 8 months earlier, but didn't realised few things like a little bit different specs and lack of temp sensor, but it was working ok (Really?!)) and POWER on.

"Warp engine on-line, plasma injectors - 105%, Warp field - stable..." :doh:

... and I was shocked: my TD4 finally got a KICK. Seriously, I've been complaining about it for a long time and now this is a different car. I had serious thoughts about changing on different platform (petrol 2.5?) but now it's gone with the wind. TD4 has potential and it's enough for me now.
So, late evening I went to work (nights, nights). Everything perfect, no smoke, no problems... Next morning: start engine, ok, route home, ok?... not ok, my car is smoking as hell. All the way home. When you press accelerator - black smoke. Sh***t. Got home in one piece, park my car, went to sleep. Next day with cleared mind, I did small research. MAF? almost new, PCV? cleaned 3 weeks earlier, so it will be ok, EGR? Hmmmm... Let's dig in and what inside? Cra**p, full of it. Cleaned and put back as it was (I found as well loads of it in the air intake, but have no time to soak with oven cleaner, so left for the future work to be done as I want to change EGR to Bypass, mine is not working anyway, constantly blocking (lucky) exhaust pipe now.
What is intriguing to me is the fact that black smoke was only in the morning (cold weather, about 16 deg C). I'm using now diesel additive "Xtra..." or something like that, so have a lot less black smoke, just sometimes small black fart will come out and nothing more. I'm awaiting test in the morning, so we will see if that will change.

I traced air route and I have a question: Did anyone thought to get rid of this black plastic box on top of inlet manifold and shortened distance of all ducting, maybe fitting force induction or similar thing?

Hi all, Im new to this site and have been very interested in the EGR mod. I read in the haynes manual that the valve is controlled by the vacuum pipe. Will removing this pipe not do the same job?? cheers guys

sammy99 said:

Hi all, Im new to this site and have been very interested in the EGR mod. I read in the haynes manual that the valve is controlled by the vacuum pipe. Will removing this pipe not do the same job?? cheers guys

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Been done many times. unplugging & blocking the small vacuum pipe does disable the egr & you may find a slight improvement in pickup at lighter throttle settings. The main problem is the egr itself as the workings block the air inlet pipe by around 40% & that's when it's all nice clean new & shiny. For best results junk the unit & fit the bypass.

Cheers, tried this today and there is definatley a slight improvement with pick up as i pull away. Can i just undo the egr valve and fit a home made blank plate i.e a stainless steel square over the hole and re fit the egr over top or would you recommend a proper job?? Sam

By the sounds of it, it won't run at all if you do that as you will be blocking the air flow completely. What you need to blank off is the small round port that leads off of the egr to the exhaust. A couple of people on the forum have tried coins etc, but found somehow holes burnt through the coin, so obviously not thick enough to take the heat. The bypass makes the larger section of the pipe straight through with no obstruction, and blanks off the small hose to the exhaust. If you have a look at one of the bypass items, you will see what I mean.

If you look at picture 5 in the first post of this thread, the hose you are trying to block is the one the goes from the front of the shot to the rear, under the word "BLANK". The main air flow is from left to right, or right to left, never can remember which way round. Any obstruction you can remove from the horizontal air flow will give an improvement.

Good Luck.

Thanks, will have a look but time's ticking as I'm off to devon monday with the caravan on the back so may just stick with the blanked vacuum pipe til after we're back. Thanks again.

Just done my conversion after cleaning EGR valve previously. As we suspect "just" cleaning is better but... so I got bypass from Ebay. That guy is selling them for about £45, but on the question what material is using (as I don't want any cheap soft steel), he start threatening me with court as his "design" is patented for "European market"... Whoa! ...I'm just asking... raise: Yes, Master...

Anyway, fitted and will be tested soon In the same time done my inlet manifold and I discovered that inlet after a some time may have some splits on the moulded edges... or that is just me... looking for problems..??

what was the address for the blank on ebay? I've seen one but it doesn't say if it'll fit a freelander, it's up for £39.99 I called a few places today but none of them sold one for a td4 and don't wanna get the wrong one. Sam

Optimus Prime said:

A couple of people on the forum have tried coins etc, but found somehow holes burnt through the coin, so obviously not thick enough to take the heat.
Good Luck.

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I've heard of others using tin can lids that have burned/blown through. I did it with a 2p piece (is that a record for the cheapest landy mod?) and it's still holding out.

Norbet said:

I've heard of others using tin can lids that have burned/blown through. I did it with a 2p piece (is that a record for the cheapest landy mod?) and it's still holding out.

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no the cheapest mod is the penny trick.Do a search on here

cheapest is to use nothing and just disconnect and block the vacuum hose. then the valve can't be opened and there is no need to blank it off.

I have blanked the vacuum pipe and it is much better. So wot will i gain by buying a proper egr blank?????? Is it worth spending the cash????

the egr which is factory fitted has a valve assembly obstructing approx 40% of the flow through the valve. Fitting a bypass has no valve assembly, so greater flow rate, hence better performance.

AllanI said:

But if you leave the EGR valve in place the internal shape offers more of a restriction than the replacement pipe which is a plain tube.

Allan

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this mod is the same one that is done to the rover 75 diesel,it has been worked out that by removing the EGR valve it gives 40% more airflow into the engine,so less hesitation better response etc,i did this on my r 75 and what a difference it made.

Don’t get carried away with this 40% thing. I doubt there is any real increase in air flow into the engine compared to a clean EGR valve. Just because there is a smaller cross sectional area it doesn’t necessarily mean that it cannot pass enough air to supply the engines needs. The boost pressure in the manifold is what matters and as long as that is able to be maintained the engine won’t suffer.

Crisper throttle response whether EGR is disabled or removed is very similar and is because there being a greater percentage of oxygen waiting in the manifold when the throttle is increased not because of any great increase in air flow.

Chaser said:

Don’t get carried away with this 40% thing. I doubt there is any real increase in air flow into the engine compared to a clean EGR valve. Just because there is a smaller cross sectional area it doesn’t necessarily mean that it cannot pass enough air to supply the engines needs. The boost pressure in the manifold is what matters and as long as that is able to be maintained the engine won’t suffer.

Crisper throttle response whether EGR is disabled or removed is very similar and is because there being a greater percentage of oxygen waiting in the manifold when the throttle is increased not because of any great increase in air flow.

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it has been worked out by the people that make the mods etc,all i know is it made my rover 75 cdti a lot easier/better to drive and better mpg.

gemsdad said:

it has been worked out by the people that make the mods etc,all i know is it made my rover 75 cdti a lot easier/better to drive and better mpg.

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They have a vested interest so they would say that.

But the point to note is a 40% change in the cross sectional area at this point does not mean a 40% change in air flow. Can the inlet valves can pass 40% more air or the intercooler?

Assuming the valve was working and sealing correctly,
if you remove a valve that looks like the first pic you will feel some improvement..
But if you remove one that's been disabled and looks like the second you'll hardly notice anything..

Just to throw my Pennies worth in.
Took the Landrover EGR valve off. Put on a pass through obtained from Eb*y cleaned the manifold with Mr Muscle and blocked the vacuum hose. The car has done around 75,000 miles and to say this made a difference is an understatement. The engine is alot smoother and back to how it used to react when we got it. Also as it's an auto box, it isn't searching for gears as much, as the power is more consistent now. Can't wait to tow the van with it to see what the difference is.

Skinny Mike said:

Just to throw my Pennies worth in.
Took the Landrover EGR valve off. Put on a pass through obtained from Eb*y cleaned the manifold with Mr Muscle and blocked the vacuum hose. The car has done around 75,000 miles and to say this made a difference is an understatement. The engine is alot smoother and back to how it used to react when we got it. Also as it's an auto box, it isn't searching for gears as much, as the power is more consistent now. Can't wait to tow the van with it to see what the difference is.

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hi S M,glad you agree its a good thing to do,some people just think its a load of hot air,(which it is i suppose),i found my rover 75 cdti to be a lot more pleasurable to drive with this mod,no hesitation on take of at roundabouts etc,better mpg and more powerful as well.

Chaser said:

They have a vested interest so they would say that.

But the point to note is a 40% change in the cross sectional area at this point does not mean a 40% change in air flow. Can the inlet valves can pass 40% more air or the intercooler?

Assuming the valve was working and sealing correctly,
if you remove a valve that looks like the first pic you will feel some improvement..
But if you remove one that's been disabled and looks like the second you'll hardly notice anything..

Click to expand...

just to say my egr valve was more like the second pic more than the first pic and it did make a big difference to the engine performance.