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Mal has hit the nail on the head so to speak as he has actually fitted blanks his self so is an ideal person to give you advice. This may help a bit all the same to get your head around it:
| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731   
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Cheers Steve
I think (hope) my confusion is because the EGR valve is on one side of the engine and the EGR pickup pipe (where the plate goes) is over the other side by the exhaust manifold... and much easier to get to (took me a while to get my head round the photos on the first page of this thread). Now I wait for the  Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing... |
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29th Sep 2012 3:09pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20333 
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Oh I see why you were confused now
 âï¸âï¸God Bless the USA 🇬🇧🇺🇸 âï¸âï¸ |
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29th Sep 2012 3:58pm |
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| john adam Member Since: 01 Sep 2010 Location: Paris Posts: 77  
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Matt,
Very interested in blanking the EGR on my LHD Puma. Please do not forget to post comments (and photos) Thanks 
Carlo 1971 88 Series IIA somewhere in Southern Italy 1989 Ninety stolen in Paris 2004 90 TD5 gone 2010 110 S Puma TDCI running |
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2nd Oct 2012 7:19pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20333
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Carlo - He's bought a 'blank' blank so to speak so needs drill a hole in it first (This is what I thought was the plan anyway) I too would be interested to see how it goes.
âï¸âï¸God Bless the USA 🇬🇧🇺🇸 âï¸âï¸ |
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2nd Oct 2012 7:45pm |
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| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731
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Actually I bought this one to start with:
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...0697422591 but eBay seems confused whether I paid for it or not 
Phoning them tomorrow... *Edit* Now that link is dead this works:
http://www.ebay.de/itm/130697422591?ssPage...1439.l2649 Assuming I don't have problems initially, I will probably drill my own "blank" blanks to experiment, as Steve says. I have an RAI but would like an Allisport IC next year which may require some hole size adjustment Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing... |
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2nd Oct 2012 8:05pm |
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| john adam Member Since: 01 Sep 2010 Location: Paris Posts: 77
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thanks for the info.
Ciao Carlo 1971 88 Series IIA somewhere in Southern Italy 1989 Ninety stolen in Paris 2004 90 TD5 gone 2010 110 S Puma TDCI running |
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3rd Oct 2012 8:00am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20333
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Ze - In the process today of fitting my new EGR valve which is now 90% completed however if you want my advice with the blanks try and avoid undoing the bolts completely at all costs if you can or you will have a lot of fun trying to get it all back into place. (Especially the gaskets) and access is VERY tight.
âï¸âï¸God Bless the USA 🇬🇧🇺🇸 âï¸âï¸ |
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3rd Oct 2012 4:10pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20333
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Well today my new EGR valve and gaskets turned up to replace my EGR that was knackered. This was also putting my MIL light on (amber dash warning light) So I fitted the new one myself and cleared the fault codes this was causing with a scanner I bought. And saved £192 on garage fees in the process.
New genuine LR EGR Valve and Gaskets:  Click image to enlarge Replaced knackered EGR (Putting MIL light on and also stopped going through the self cleaning cycle as it should the "chuka chuka noise on engine shut off) The DTC this was causing was basically showing as "valve stuck closed" probably due to carbon build up. Click image to enlarge Click image to enlarge EGR Valve mating faces. These need to be cleaned before fitting the new one and gaskets. This was pre cleaning. Click image to enlarge âï¸âï¸God Bless the USA 🇬🇧🇺🇸 âï¸âï¸ |
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3rd Oct 2012 7:29pm |
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| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731
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I'm not going to touch the valve joints (rather you than me) - the blanking plate I bought has open holes so it can just slip in between the exhaust manifold and the EGR pickup ("cooler") pipe, without undoing the stud nuts entirely
I'd be interested to know how much "give" there is in the EGR pipework - they're all solid metal aren't they? Just to irritate Mal (sorry) I asked him whether there is a gasket at the exhaust manifold joint (the one I need to break). I seem to remember someone saying there isn't one, but it's hard to believe considering the pressure that must build up there (think how critical the turbo gasket is). God knows where I could get such gaskets from - I'd need two I guess. Anyway, the plate will arrive in a day or two, so for now I am comparing power and consumption with the LR factory map and the EGR working or disconnected (the Scangauge kills the MIL every three cycles). Then I can compare how well the "holed" blanking plate works once I'm convinced I can fit it without the engine screaming like a banshee... again Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing... |
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3rd Oct 2012 7:51pm |
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| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731
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Incidentally, top job on the EGR
Pictures are great and really useful Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing... |
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3rd Oct 2012 7:52pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20333
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Thanks Matt
Hardest part is getting access to put the replacement back in and of course the gaskets always wanted to fall out before the bolts lined up with the holes âï¸âï¸God Bless the USA 🇬🇧🇺🇸 âï¸âï¸ |
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3rd Oct 2012 7:55pm |
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| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731
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Thought y'all might like to know the results of my first EGR comparison. I only compared noticeable parameters such as top speed, noise, power and fuel consumption. I know I could have looked at boost etc. but it's not really something you can "feel". Vehicle was on factory map with hardware speed unlimiter. Each data set consists of 3 runs on the same stretch of dry roads (city and autobahn) and under essentially the same conditions. So here we go:
With EGR valve operating normally: Noise level at idle - 63dB Noise at 2000rpm (stationary) - 73db Noise at 2000rpm (100km/h) - 82dB Top speed - 150km/h Peak power at top speed (ScangaugeII) - 87hp Best fuel consumption on "granny run" - 8.6L/100km EGR valve disconnected: Noise at idle - 63dB Noise at 2000rpm (stationary) - 73dB Noise at 2000rpm (100km/h) - 80dB Top speed - 154km/h Peak power at top speed - 89hp Best fuel consumption - 8.3L/100km Subjectively, without EGR, top speed increase felt much smoother and quieter and the 110 got up there quicker (no specific measurements though - too dangerous staring at Scangauge). Also, there seems to be less clatter at higher revs and lower speeds (especially in 2nd). Fuel consumption difference in "real" numbers is about 1mpg. Also bear in mind that the dB noise scale is logarithmic, so when you subtract road/wind noise the difference between 80 and 82dB is also quite significant (possibly 1/2 as much again). It certainly seemed quite a bit louder. In summary, then, disconnecting the EGR increases peak power and top speed by 1% and improves fuel consumption (driving carefully) by about 2%. It wasn't actually that annoying to cancel the MIL every 3 cycles.
Next step is to blank the valve off leaving a 10mm hole. Tell someone you love them today because life is short. But shout it at them in German because life is also terrifying and confusing... |
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8th Oct 2012 10:56am |
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| john adam Member Since: 01 Sep 2010 Location: Paris Posts: 77
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Thanks for the figures. Just one point: does noise decrease without EGR (82 to 80 dB)? Isn't it?
Carlo 1971 88 Series IIA somewhere in Southern Italy 1989 Ninety stolen in Paris 2004 90 TD5 gone 2010 110 S Puma TDCI running |
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8th Oct 2012 7:27pm |
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| ZeDefender Member Since: 15 Sep 2011 Location: Munich Posts: 4731
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Yes, noise decreases when the EGR valve is disconnected. The figures don't really reflect the feeling - when everything is combined, driving is just that bit better without EGR. So that convinced me to fit the drilled blank (as soon as my un-broken torque wrench arrives). I'll see then if it's as good as disconnecting the valve entirely
And when the "victim downpipe" arrives...  Tell someone you love them today because life is short.
But shout it at them in German because life is also terrifying and confusing... |
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8th Oct 2012 7:34pm |
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