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ian964

Member Since: 01 Jan 2010
Location: Surrey
Posts: 30

2007 Defender 110 Puma 2.4 XS CSW Java Black

EGR Valve Stuck Open?

I've been having a bit of a problem with the car today, I think because the EGR valve may be stuck. Car was running fine (with BAS remap, pre EGR close version). I stopped for 15 minutes, then when I restarted and drove off, there was no power and loads of grey smoke from the exhaust. Power picked up a bit if the revs went over 2000, but still loads of smoke. MIL light came on as well.

I've tried putting back the original map and clearing the fault codes, but this has made no difference. MIL light is off, fault codes showing now are P0100 (Mass or volume air flow circuit) and P0404 (Exhaust gas recirculation control – circuit range/performance). The EGR cleaning cycle on switch off is NOT happening now, whereas it had been previously, which is what makes me think the EGR is stuck, does this seem a reasonable assumption?

Next step is to remove and clean the EGR valve, at least to make sure it is closed, however I'm not sure how/where it is. Can anyone please give me a few pointers on removing it?

Thanks
Ian

4th Feb 2012 10:35pm

K9F

Member Since: 12 Nov 2009
Location: Bournemouth
Posts: 9610

2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey

Not removal, but this thread should point you in the general direction, would suggest using brake cleaner as cleaning agent.

http://www.defender2.net/forum/topic2227.html?highlight=egr+blank

Page three on this thread too shows you where it is in photos...

http://www.defender2.net/forum/topic3115.h...p;start=30 If you go through life with your head in the sand....all people will see is an ar5e!!

Treat every day as if it is your last....one day you will be right!!

4th Feb 2012 11:39pm

BIGFOG

Member Since: 12 Sep 2010
Location: Edenbridge
Posts: 537

2009 Defender 110 Puma 2.4 USW Stornoway Grey

Turbo hoses all sound? 2009 XS 110 Utility Stornaway Grey
BAS re Remap, BAS Turbo, BAS Spec Modified Airbox, Twisted Side exit Decat Exhaust, Allisport Cooler and Hoses, OME Sport Shocks, Kangaroo Paw Discs.
2001 Discovery II
Porsche Speedster Replica 1956ish

5th Feb 2012 9:00am

ian964

Member Since: 01 Jan 2010
Location: Surrey
Posts: 30

Thanks for these - turbo hoses look OK, EGR valve located now! I'll try giving it a tap first,then take it off and clean f that doesn't work.

cheers
Ian

5th Feb 2012 11:07am

ian964

Member Since: 01 Jan 2010
Location: Surrey
Posts: 30

Well a few whacks with a hammer (the handle rather than the other end!) seems to have freed things up, and the car is running normally for now. The EGR probably should be replaced, but I'll see if I can get the EGR update to the BAS remap and try that now the valve closes.

Cheers
Ian

5th Feb 2012 12:47pm

wslr

Member Since: 18 Jul 2010
Location: Wellington, Somerset
Posts: 581

You can get an EGR cleaner which you spray into the air inlet when the engine is on a fast idle.

On the quiet, LR were doing this when the D3 was going through early EGR issues, just to keep the vehicles going for customers before they could get them into the workshop.

Here is the product:
http://www.wynnoil.co.uk/products-wynns-featured-egr3.htm

5th Feb 2012 12:59pm

Lorryman100

Member Since: 01 Oct 2010
Location: Here
Posts: 2686

Now that it is working again, unplug it (after cleaning cycle so you know it is closed) and get the EGR closed upgrade fitted soon as. You will get the MIL on and a couple of DTC's and maybe limp mode the first time you start after removing the plug, just switch off and restart to clear the limp mode and live with the MIL until the egr remap is on.

5th Feb 2012 1:06pm

ian964

Member Since: 01 Jan 2010
Location: Surrey
Posts: 30

Lorryman100 wrote:
Now that it is working again, unplug it (after cleaning cycle so you know it is closed) and get the EGR closed upgrade fitted soon as. You will get the MIL on and a couple of DTC's and maybe limp mode the first time you start after removing the plug, just switch off and restart to clear the limp mode and live with the MIL until the egr remap is on.

Done just this, MIL light on but otherwise all fine.

Thanks
Ian

5th Feb 2012 5:04pm

Bryden

Member Since: 27 Dec 2011
Location: Springs
Posts: 9

2008 Defender 110 Puma 2.4 SW Stornoway Grey

I have had a slightly different experience, my 2008 was my first Defender and initially ran like a pig, better after freeing up the turbo actuater. It then accelerated slowly up to 2200 rpm before taking off on turbo boost. even though it had the normal click-clack from the egr on shutdown I decided to unplug the egr from the loom.
A test drive revealed a completely different vehicle that now pulls well from 1500 rpm and will accelerate up a slight slope in 6th gear from these revs. I have no engine light on but wait in anticipation.

6th Feb 2012 7:58am

Naks

Member Since: 27 Jan 2009
Location: Stellenbosch, ZA
Posts: 2638

2010 Defender 90 Puma 2.4 SW Alpine White

Bryden wrote:
I have no engine light on but wait in anticipation.

that is very strange...

What do mean by 'freeing up the turbo actuator'? --
2010 Defender Puma 90 + BAS remap + Alive IC + Slickshift + Ashcroft ATB rear
2015 Range Rover Sport V8 Supercharged

Defender Puma Workshop Manual: https://bit.ly/2zZ1en9
Discovery 4 Workshop Manual: https://bit.ly/2zXrtKO
Range Rover/Sport L320/L322/L494 Workshop Manual: https://bit.ly/2zc58JQ

6th Feb 2012 8:57am

Bryden

Member Since: 27 Dec 2011
Location: Springs
Posts: 9

The plate that activates the turbo variable angle vanes was stuck, a few taps freed it

6th Feb 2012 9:14am

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