Blanking/ Removing Egr Valve?

i have an m reg discovery 300 tdi auto been reading about blanking/ removing the egr valve fow the last week or so.
sounds easy enough, but i have a few questions....

1. which way is the best to do it.

just fit blanking plate between valve and leave everthing in place where it is/ or replace top hose fit blanking plate and remove every thing?

2. people have mentioned the black gunge, some have just scraped it out and others have striped it down and cleaned with an assortment of fluids etc. does this have to be done as some have some haven't, and if so what tas to be removed and what has to be cleaned/with what.

asked this as the first way of blanking plate does not mention striping or cleaning just putting the blanking plate in. would leaving gunge cause problems later?

any clear advise would be welcome from people who have done this and which way they used, and any comments they may have on either way.

i've also read many people did not notice any difference once they blanked ther egr?

if blanking the egr saves fuel/money and makes discovery run better i can'y wait to get my kit ordered and get on with it.

go for option 2 hose & plate. and clean your intercooler out best way is to stuff a rag in one end and pour a litre or so of petrol in it. Then blank top hole and shake well. If it's full of gunge it's restricting the airflow.

Mark, where abouts in the West Mids are you?

the gunge restricts the air flow, the mess in your intercooler reduces it's efficiency to cool the charge air. Hotter air = less engine power.

giving up smoking dont turn you into an athelete... but it'll help you breathe better..!

See picture

EGR blanked at manifold
New top hose replaces old one

300 TDi

I blanked mine off imediately after the valve (couldn't get the exhaust manifold bolts undone) and then took off all the EGR pipework and replaced it with a direct intercooler to manifold pipe.

I did look in the inlet manifold and there was marmite in there, but I haven't yet cleaned it out. Also I haven't yet cleaned the intercooler either but I plan to do both soon.

I would go for option two, get a new gasket for your manifolds and take the inlet manifold off for a good cleaning. Kero is your best bet to clean out the manifold/intercooler.

You can use any wide enough internal diameter pipe (use internal diameter of the inlet to the inlet manifold as a guide size) to replace the top hose section with - I used a piece of scaff bar to replace it.

discomania said:

I would go for option two, get a new gasket for your manifolds and take the inlet manifold off for a good cleaning. Kero is your best bet to clean out the manifold/intercooler.

You can use any wide enough internal diameter pipe (use internal diameter of the inlet to the inlet manifold as a guide size) to replace the top hose section with - I used a piece of scaff bar to replace it.

Click to expand...

are you talking about a TD5? inlet in the 300 is an s shaped hose

i was lucky, managed to find a steel pipe with a bend in it just about right for the top hose for my 300

battenberg said:

See picture

EGR blanked at manifold
New top hose replaces old one

300 TDi

Click to expand...

Did you notice performance improvement and any change in fuel consumption? Been giving serious thought to doing mine and those pics you posted are clearest method seen yet. Tks.

Miles000 said:

Did you notice performance improvement and any change in fuel consumption? Been giving serious thought to doing mine and those pics you posted are clearest method seen yet. Tks.

Click to expand...

To be honest No... but dont be fooled by that statement. I ordered the EGR blanking plate the day I put the deposit down on the car. It was the first thing I did when I got it home..!

However, I ran my TD5 for a few months before blanking it off and the gunge left behind, and the performance difference was enough for me to Blank the 300 without any further question.

Dont **** about - Loose the EGR right now - you will be amazed at the mess its already made of your engine !!!

battenberg said:

are you talking about a TD5? inlet in the 300 is an s shaped hose

Click to expand...

Nope the 300tdi; I had to cut the ends at angles so the pipes could sit unkinked...

ordered egr blanking kit last night

have gone for the complete kit - blanking plate, gaskets bolts and new top hose. had it off ebay £18.99 complete, don't know if that price was good/bad but i thought was reasonable for what's in the kit.

have wd'd bolts few times already in prep.

will let you know how i get on and what difference it makes.

would still be interested in how others got on if they have done theirs,
or are about to do theirs......

Sounds like the same kit I bought. I had trouble getting the manifold bolts off, so I disconnected the intake pipe immediately after the EGR valve, blanked of there and then took away all the existing EGR plumbing.

I find my car runs noticeably better now, especially going up hills oddly enough - seems to hold it's speed easier. Fuel consumption is improved also. Getting well over 30 mpg.

i'll have to see how i get on, but good to know.

hoping it will help mine with hills! thought it was me to begin with untill started reading on this site.
especially on the motorway! flying at 70 untill hill and down to 50 ish then past hill 70+ again?
the better mpg is a bonus too!

dont expect miracles!

but expect a slight improvement...
Just be satisfied that you are giving your engine a new lease of life by removing that gunge creating EGR rubbish from it's fresh air intake, You may want to treat the ol' girl to a new air filter as well.

that sounds great too me as just recently changed air filter and the differenct in doing that was unbelevable so any thing helps

kit arrived today!

with colour instructions too.... but doesn't mention cleaning the intercooler

does any one have any coments on what to clean intercooler with, how long it takes/before can put back together.

accessory shops in this area are not too helpfull with some things ive seen being suggested.

is there something easy such as petrol/diesel etc ????

any comments will be greatfully recieved

I bought the full kit off ebay too. I finally got around to fitting it today. I had problems getting at the egr valve to manifold bolts due to the bolts for the egr pipe being in the way. I decided to remove them first. The pipe to egr valve bolts came out easy with a bit of wd40. Once they were out the way I tapped a rounded nut remover over the egr to manifold bolts and they flew out. I fitted the new hose too but I didn't have time to sort out my intercooler so it'll have to wait for another day.

markw said:

kit arrived today!

with colour instructions too.... but doesn't mention cleaning the intercooler

does any one have any coments on what to clean intercooler with, how long it takes/before can put back together.

accessory shops in this area are not too helpfull with some things ive seen being suggested.

is there something easy such as petrol/diesel etc ????

any comments will be greatfully recieved

Click to expand...

i used petrol to flush mine, can get proper stuff but the price is vertical!!!
easy job, doesnt take long to actually get it out and back in-its the drying out bit. i had it out most of the day but you don't have to leave it that long

done it !!!!! got rig of egr value and replaced top hose

like a new car, sounds and feels a lot better seems more responsive

loads of black liquidy like cream crap in old hose.

lookforward to saving money now from improved mpg now engine has new lease of life.

only took 20 mins guess i was lucky with the bolts holding egr valve on
just cracked and then came straight out. (had been wd ing all week though)

will keep you all informed of how it get on fuel wise now, but not sucking that crap in can't be any worse.