Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
EGR Valve - How To...
The biggy, the one we all love to hate, EGR Valve…
This is an O/S 07MY valve, which is pretty similar to pre07’s, just the bolts holding the valve onto the cooler go a different way, but I will point it out as I get there. And on the N/S, the dipstick tube and the turbo boost pipe both get in the way of that valve. Hopefully ill get some to do and edit this post with the differences… And apologies for the poor pics…
Anyway, start by removing the engine cover, and brake fluid reservoir cover (for the N/S valve, battery cover and battery). Then remove the side panel of said box. Undo screw holding coolant pipes onto lower part of the box.
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Then undo the 3x 13mm nuts circled, and remove lower tray
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With that out the way, you can see the offending little bas…. Valve
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Some clearer pictures of both sides of valves with the body removed (for reference only, dont need to remove the body to do them!)
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Remove clip from upper part of pipe with screwdriver
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Remove 8mm bolt approx half way up the pipe, holding it to the cambelt cover, and the 2 holding the lower part of the pipe to the valve. Unplug electrical connector from valve
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Remove 3x 8mm bolts holding the valve onto the side of the block, forgot to circle them before uploading. You almost cant see one. The turbo boost pipe gets in the way on the N/S valve
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Undo the 10mm bolt holding the fuel pipes to the engine
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The valve is held onto the cooler with 2 Torx30 bolts, the front one is easy enough to get out, but the inner one is a c** k. Not the 8mm bolts. Its these bolts that are different between pre and post 07MY’s…
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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated My D3 Build Thread
Last edited by Disco_Mikey on 24th Jul 2010 11:10 pm. Edited 3 times in total
27th Feb 2009 9:16 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
Now place a big lever down between the egr valve and engine block, allowing access to inner bolt
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This is the best picture I could get of the inner bolt, unfortunately… Arrowed is what you can see of the tool… If its any help, the bracket to the left of the arrow is that of the fuel pipes…
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Look at the big empty gaping hole…
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These are the gaskets you need. Also, bin the 2 T30 bolts, and get 2 bolts, same as the ones the hold the pipe onto the valve body. Much much easier than messing about with those stupid bolts…
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To refit, put the outer bolt in the hole and hook the gasket over it. Lower the valve into place and start the bolt.
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Once it is almost all the way in, attempt the inner bolt. I found covering the head of the bolt in grease holds the bolt in place until it is started. Be careful, because if you drop it, its highly likely it will never be seen again.
Refit everything that was removed, and take for a road test. On pre07, there is no EML to contend with, just a huge regain of power. On 07>on, the EML will go off after 3 clean starts (no faults)
Alternatively, fit EGR blanks, available from a few members here
Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated My D3 Build Thread
Member Since: 04 Aug 2005
Location: Newbury
Posts: 6861
another great guide DM and theeeeennn......???
27th Feb 2009 9:26 pm
crazy
Member Since: 27 Jan 2008
Location: Near Milan
Posts: 1852
Very good!!! Compliments.
CiaoLandy lover
Membro del Club
1st Mar 2009 8:45 am
DiscoDunc
Member Since: 08 May 2006
Location: Bristol
Posts: 16390
according to the LRA guy i spoke to last week, a New 2 pence piece is just the correct size to blank off the valves Duncan
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If I'd known I was going to be so thirsty this morning I'd have drunk more beer last night.
FFRR Autobiography 4.4 SDV8 MY17
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D4 HSE MY10 SOLD
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5th Mar 2009 2:42 pm
BrumLee
Member Since: 07 Mar 2008
Location: West Midlands
Posts: 1364
Mikey, nice write-up do you have a price for the valve?
5th Mar 2009 3:03 pm
DiscoDunc
Member Since: 08 May 2006
Location: Bristol
Posts: 16390
how long did it take to complete Duncan
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If I'd known I was going to be so thirsty this morning I'd have drunk more beer last night.
FFRR Autobiography 4.4 SDV8 MY17
D4 HSE MY13 SOLD
FFRR 3.6 Vogue TDV8 SOLD
D4 HSE MY10 SOLD
D4 SE TECH MY15 SOLD
D4 XS MY12 SOLD
D4 HSE MY10 SOLD
D3 HSE MY06 - Re-Cycled Worldwide
5th Mar 2009 3:55 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
Dunc: Tis true, LRA do use 2p pieces to blank them off to allow you to carry on and save on getting you recovered
I would allow 2-3 hours to do each side if you havnt done one before
Lee: IIRC, a pre 07MY valve is approx £130 + VAT each side, and an 07>on are (i think) about £90 + VAT each
Member Since: 16 Sep 2008
Location: London
Posts: 349
Mikey,
Just like to say thanks for a very informative guide and no apologies needed for the photos, they were spot on.
I completed a change of the offside EGR valve today on my 05MY. It took me about 4 hours to do but that included a couple of views of this thread mid way through and retrieving a torx socket from the sump guard
What I would say is that if anyone is attempting this make sure you have a range of small to medium extension bars because it was these that allowed me to get a socket in the right place to get to the 2 Torx bolts that secure the EGR valve to the cooler.
Cheers,
John
25th May 2009 9:43 pm
irl32
Member Since: 27 Aug 2009
Location: Co Mayo
Posts: 66
A fantastic bit of work But how did you know whick one needed changing, and is it possible to blank the valve of on a 06 TDV6.
Where or who can i get to read the codes
Last edited by irl32 on 28th Aug 2009 10:47 am. Edited 1 time in total
27th Aug 2009 1:37 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
Member Since: 14 Jan 2009
Location: limpopo
Posts: 5
EGR BLANKING
i can remember that there was a another set of fotos , it was fotos of 2 buddies that day with a case of beer and doing it in 3 hoursG4 Edition , TDV6S , BF Goodrige 265x75x17 ,
Dual Battery , Longrange tank , Sparewheel carrier(swing-out) , ARB Bumper with WARN winge.
You cannot post new topics in this forum You cannot reply to topics in this forum You cannot edit your posts in this forum You cannot delete your posts in this forum You cannot vote in polls in this forum
But how did you know whick one needed changing, and is it possible to blank the valve of on a 06 TDV6.
