Keep the EGR Valve, Remove It, Or Blank It Off

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NinkyNonk

Active Member
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172
I think my Defender is throwing a wobbly because I haven't used it much recently. I noticed over the weekend that the two rubber hoses which connect the pipe between the intercooler and the inlet manifold on my '96 300tdi are looking quite sorry for themselves. Have looked around online and I can't seem to find anywhere that stock the two individual rubber joints, just a replacement silicone pipe without EGR connection. Maybe I'm looking in the wrong places, or maybe I'm a bit thick?

Contemplating whether I should bother doing away with the EGR valve completely, blank it off and leave it in place, or just buy the silicone pipe and cut the ends off and leave it as is. Have spent the last day reading threads about removing them but I'm a bit wary of snapping bolts off in the manifold if I try to take it off, and also feel blanking off the brake servo pipe seems a bit rough by just winding a bolt into the end of it.

Any advice would be appreciated. I've got some plus gas which I could give it a bit of a soaking with for a few days or a week if that may help.
 
Cutting the new pipe is probably the easiest but I would perservere and remove and blank the egr.
 
That makes sense, I'll buy the blanking kit from eBay and then if the bolts come out I can remove it, if not I'll just butcher the new pipe and replace the two joints!!

Part of me wants to see if it makes any difference anyway.
 
While you are at it clean the intake manifold (best to remove it and use gunk or petrol) as it will be caked in sticky / oily residue which wont help things. I did it when I got mine but kept all the old bits just in case some new MOT ruling appears in the future which requires it to be fitted if it was originally (a bit like the Cat convertor requirement than no one checks on! :rolleyes:)
 
Kwakerman said:
While you are at it clean the intake manifold (best to remove it and use gunk or petrol) as it will be caked in sticky / oily residue which wont help things. I did it when I got mine but kept all the old bits just in case some new MOT ruling appears in the future which requires it to be fitted if it was originally (a bit like the Cat convertor requirement than no one checks on! :rolleyes:)
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:)I will if it looks overly dirty, bit worried all the studs will come out of the block or something stupid. Probably end up with a driveway full of engine parts and not a clue how it goes back together if I'm not careful though. If the EGR valve comes off it'll go into my box of bits along with all the other stuff I've been meaning to fit.

Not to worry the garage will be finished soon and I'll be able to work in relative comfort. Thanks for the advice :cool:
 
Kwakerman said:
While you are at it clean the intake manifold (best to remove it and use gunk or petrol) as it will be caked in sticky / oily residue which wont help things. I did it when I got mine but kept all the old bits just in case some new MOT ruling appears in the future which requires it to be fitted if it was originally (a bit like the Cat convertor requirement than no one checks on! :rolleyes:)
Click to expand...
Easiest way is to get hold of another inlet manifold. When your old lady is going to be out for a few hours simply put it in the oven at max heat for half an hour. Leave the kitchen door open and turn the extractor on. The oily residue will turn to ash and simply brush out. Then just swap manifolds and flog the dirty one. You dont need to keep it as the clean manifold will stay clean with no EGR.
 
Just a quick tip. Try to buy a 6mm long allen socket. That way you can get it onto your 3/8" or 1/2" ratchet and apply sufficient leverage to undo the bolts.
 
Afraid to say after all of the talk I have ended up putting the blanking plate between the EGR valve and the inlet pipe. I'll look into removing it when I can afford to snap stuff off and not worry about having an unusable tratter. Will soon have a garage to work out of the elements too.

Can't believe how much sh!te there was after the EGR valve in the pipe work and inlet manifold. Cleaned it up as good as possible for now but it's truly a horrible tacky mess and I'll probably look into it all over the Christmas break.

I have access to some reasonable tools although the 6mm hex socket I have won't fit square in the bolts, so feel I'd run the risk of rounding them off, may try and beg/borrow/or steal a long one at some point.

Only driven 5 miles to check it ran OK afterwards but all seems well, possibly pulling slightly smoother than before or it may just be a placebo effect.

Thanks for all the tip, I'll bare them in mind when I finally get the chance.
 
So long as blank fitted I wouldnt worry about the manifold unless the inlet is obviously restricted.
 
NinkyNonk said:
I think my Defender is throwing a wobbly because I haven't used it much recently. I noticed over the weekend that the two rubber hoses which connect the pipe between the intercooler and the inlet manifold on my '96 300tdi are looking quite sorry for themselves. Have looked around online and I can't seem to find anywhere that stock the two individual rubber joints, just a replacement silicone pipe without EGR connection. Maybe I'm looking in the wrong places, or maybe I'm a bit thick?

Contemplating whether I should bother doing away with the EGR valve completely, blank it off and leave it in place, or just buy the silicone pipe and cut the ends off and leave it as is. Have spent the last day reading threads about removing them but I'm a bit wary of snapping bolts off in the manifold if I try to take it off, and also feel blanking off the brake servo pipe seems a bit rough by just winding a bolt into the end of it.

Any advice would be appreciated. I've got some plus gas which I could give it a bit of a soaking with for a few days or a week if that may help.
Click to expand...
Get rid of it. If you don't want to I have a 300tdi egr set of pipes you can have off of mine for a few quid.
 
Coffeelandy said:
Get rid of it. If you don't want to I have a 300tdi egr set of pipes you can have off of mine for a few quid.
Click to expand...
Thanks for the offer, I'll get rid of it at some point just when I can comfortably do without it for a while if the proverbial decides to hit the fan.
 
So been driving it for the last week and have just put some fuel in it. Alarmed at how quickly the fuel went down, about 1/2 tank to 153 miles, worked out at 15mpg. Before this I'd quite often get about 26-29mpg during normal use!

Could it be that the egr valve has been blanked off and not electrically disconnected be making any odds? Or is it just a coincidence that something has gone wrong at the same time?
 
Did you measure it brim to brim? if not your mpg figures are irrelevant.
The only time the egr on a 300 will cause problems is when its stuck open, the car simply isnt clever enough to act any differently.
Of course someone could be helping them selves to your fuel!
 
lynall said:
Did you measure it brim to brim? if not your mpg figures are irrelevant.
The only time the egr on a 300 will cause problems is when its stuck open, the car simply isnt clever enough to act any differently.
Of course someone could be helping them selves to your fuel!
Click to expand...
Yeah, brim to brim, I'm sad git like that I always remember the figures and calculate them. I did think the same about someone possibly half inching some fuel but can't see any damage to the lock or cap. Also wondered if the nozzle picked up a bubble or something and didn't fill the tank 100% before clicking off. Normally I drive home then add some Millers Ecomax and check if can still see diesel down the filler neck but forgot last time. Will see how this tank lasts and start to worry if I achieve stoopid mpg again.

Cheers for replying though :)
 
There is no way a blanked egr can use more or less fuel. EGR has nothing to do with fuel economy it is merely to try and limit NOX emissions by cooling the exhaust gasses because the engine inlet has reduced Oxygen when the egr is open. Egr does have a slight effect on emissions but at the expense of the cleanliness of the inlet tract. Also the particulates kicked out by any diesel engine are far more harmful than the slight decrease in NOX emissions.
 
150 miles on half a tank sounds about right to me, if you class "half a tank" as the amount needed to go half way between "yellow light on" and full.
 
I didn't think it would make any odds either, unless I accidentally made a mistake when calculating the mpg or something.

I'll be filling it up one night this week so will recalculate and see how many mpg it's done to this tank. It is going to be serviced soon anyway so that may be reducing the fuel consumption a little as well as the cold weather.
 
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