martinfiattech wrote:

Come on lads it`s an egr valve it`s not rocket science.
The same engines in Fiat ducato`s, peuegot boxer, citroen relay. and a few others.
If access is an issue LET THE FRONT TYRES DOWN.

Two 10 mm hex headed bolts into egr from heatexchanger.
Two 8 mm hex headed bolts from egr into induction pipe towards inlet manifold.
Don`t mess about with fitting new allen or torx bolts. As when they corrode they will round off much quicker.
It`s replaced in a hour, check the electrical multi plug for corrosion it can and does corrode.

If your worried about the bolts snapping get it stinking hot first. Slacken the two 8 mm headed bolts first.
This will stop the steel tube going into the inlet manifold from twisting on it`s axis. It`s made of chocolate, then carry out same to the others. leave to cool and serve with Jaffa cakes and fresh mug of tea !

Yes the bolts can and do snap put steel thru ally it will corrode !
Examine the bolts on removal if ok re fit. Myself I put some coppa slip on them for the next person, it may be me.
You don`t really need a torque wrench common sense and a short spanner is all that's needed.
If the bolts do snap, and this happened to me on Tuesday.
2.2 puma engine fiat ducato with 185,000 miles behind it just whip out the steel tube. 1. 10 mm bolt to block and two 8 mm short screws into plastic inlet manifold.
Drill the remains out nut and bolt straight thru, you don`t need to go all fancy with re tapping treads.

On the subject of the steel tube that goes into the inlet manifold from the egr valve, I have had that block up.
This has given rise to egr insufficient flow faults, this is usualy accompanied by black smoke.
This is always on vehicles of low mileage / short runs. such as my own defender now 1700 miles since I got it in November !!!

I`ve fitted hundreds of egr valves to vehicles over the years, if you want a good one may I suggest the new merc sprinter om 651 twin turbo engine .
Standard merc time 5.3 hours. 3 hours of which you will spend upside down.

As for the old wifes tail of blocking it off. Yes you can put a plate in with a 10 mm hole init to restrict flow, I`ve done 20 or 30 transits with out issue. I thought it was a waste of time but he was paying me so what do you do !!

If you choose to fully block it off with out the ecu being re programed, at some point it will recognise a low thru the egr via the air flow meter, as it expects to see a reduction in measured air mass while egr cycling.
After all the air has to come from some where.

Happy mending to all, off to drive the defender for the first time this week.
Since my hols I`ve put on half a stone so I`ve been biking it to work. Door to door 2.5 miles in 7 minutes, it`s quicker than the car and much cheaper on the fuel to.