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matchap801

Member Since: 05 Aug 2021
Location: Somerset
Posts: 120

2009 Defender 90 Puma 2.4 CSW Zermatt Silver

Puma 2.4 EGR Valve Remove & Clean

Phew. Glad it’s done and sorted. Apologies no photos. I keep forgetting.
My CSW has been running a little badly - judder on gentle throttle poor acceleration and fuel economy.
So I bit the bullet and parked it up in the garage and set to work.
Removed and cleaned the intercooler. Removed and cleaned the EGR Valve and VCV - ALL flushed with brake cleaner. Removed and cleaned the Inlet Manifold - really dirty with the oily spot blocking around 50% of each port. All the Muck scraped out and and flushed with brake cleaner. The inlet ports were also very badly blocked so these were very carefully cleaned.
All fitted back together - the EGR is a pig of a thing to refit, I lost a lot of skin off my hands. But eventually all refitted.
Reconnected the battery and and few spins of the starter to check no issues. Then a proper start - it ran a little rough, but left to idle for 5 minutes, checked all over then Road tested. Judder on drive appears to be gone - lots of the engine noise gone. Accelerates nicely.
I will be using FORScan on Saturday to reset the VCV and see how it goes. 2009 Defender 90 CSW 2.4 TDCI.
Ex Army Mechanic still living the dream.

18th Mar 2022 11:21pm

MartinK

Member Since: 02 Mar 2011
Location: Silverdale (Lancashire/Cumbria Border)
Posts: 2664

2011 Defender 110 Puma 2.4 USW Orkney Grey

Need to have a go at my EGR, I'll probably buy a new one and swap it then clean the original and keep it on the shelf till next time.

Thanks for sharing Defender "Puma" 2.4 110 County Utility (possibly the last of the 2.4's)

19th Mar 2022 3:20pm

matchap801

Member Since: 05 Aug 2021
Location: Somerset
Posts: 120

My EGR was in good overall condition. I stripped I’d down to clean all the gears.
I bought a 5 litre can of brake cleaner from eBay - was awesome as a flush and cleaner for the intercooler and inlet manifold! 2009 Defender 90 CSW 2.4 TDCI.
Ex Army Mechanic still living the dream.

19th Mar 2022 3:39pm

MartinK

Member Since: 02 Mar 2011
Location: Silverdale (Lancashire/Cumbria Border)
Posts: 2664

The top 2 bolts (10mm and 8mm) on the EGR are easy to crack (I managed to loosen them), but the lower are a pig to access. I'll need to invest in a pair of smaller hands. Unless there's a secret way of accessing them...
I'll plan a day to have a longer go at the job. Maybe I'll buy a flexible extension bar first. Defender "Puma" 2.4 110 County Utility (possibly the last of the 2.4's)

23rd Mar 2022 8:09am

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