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Jonno



Member Since: 06 Mar 2012
Location: Yorkshire
Posts: 234

United Kingdom 2011 Defender 90 Puma 2.4 HT Santorini Black
EGR Swap how to...
Hi all,

I've maybe stupidly bitten the bullet and aquired a new EGR.

As the car won't fit in the garage and its about 3.5 C and blowing a gale I haven't put much effort in to trying to fit it yet.

The question is to those that have had the pleasure, how difficult / annoying is it to do?

A quick glimpse under the bonnet indicates you can barely see the thing through the maze of hoses etc.

Can the bolts be removed and the EGR swapped without much dismantling or is it a royal PITA....

Not looking for a step by step guide just a yeah 30 mins and a few skinned knuckles or it's a *loody pig and it'll take half a day...


Jonno
Post #404169 3rd Mar 2015 5:46pm
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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
Interested myself as the chucka-chucka is back even though it was replaced a year ago...
Post #404171 3rd Mar 2015 5:54pm
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Jonno



Member Since: 06 Mar 2012
Location: Yorkshire
Posts: 234

United Kingdom 2011 Defender 90 Puma 2.4 HT Santorini Black
Bizzarly on mine the chucka chuck is when its happy, it's now more of a grind, clank clank.

Will have to see what noise the new one makes once fitted.

If it's a long job it might have to wait until the weather gets a bit better....

Jonno
Post #404173 3rd Mar 2015 6:01pm
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JaffaTheNeste



Member Since: 02 May 2010
Location: Helsinki
Posts: 10

Finland 2008 Defender 90 Puma 2.4 CSW Stornoway Grey
The chukka chukka- sound after shutting down means it is working properly. Cleaning cycle.
Post #405075 6th Mar 2015 5:39pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20367

United Kingdom 
Not much dismanteling but it's a pain in the ass for acess and is very time consuming for a small thing.
I'd highly recommen spraying the bolts with WD40 the day before to soak.
Then when undoing them ease them undone slowly. (Best practice in my opinion)
Post #405085 6th Mar 2015 6:04pm
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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
JaffaTheNeste wrote:
The chukka chukka- sound after shutting down means it is working properly. Cleaning cycle.


Unless chukka chukka becomes CHUKKA CHUKKA!
Post #405118 6th Mar 2015 6:59pm
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theorangebandit



Member Since: 03 Jun 2013
Location: Stowmarket
Posts: 862


Click image to enlarge

Here's a pic of how the EGR is plumbed. It has four 10mm headed bolts
Post #405122 6th Mar 2015 7:11pm
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x-isle



Member Since: 26 May 2011
Location: Midlands
Posts: 1327

Wales 2007 Defender 110 Puma 2.4 XS CSW Santorini Black
It's pretty easy, but akward to get to. As mentioned it's just 4 bolts, but are hard to get your hands to without loosing some skin.

Shouldn't take any longer than about 30 mins to do. Just don't drop one of the bolts like I did as it fell down the side of the alternator and took ages to get it out with a telescopic magnet.

If it's cold, then do it with the engine warm, but not hot as you'll burn your hands! Laughing

I am going to take mine off in the future to clean it out and was going to do a how to at the same time, but that'll be a while off yet. Craig Rogers

2007 Puma 110 XS
2011 Evoque Coupe Dynamic Lux
www.craigrogers.photography
Post #405137 6th Mar 2015 7:45pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20367

United Kingdom 
Or get a tune with EGR delete, then you fit a solid blank and that's it forever.
Post #405143 6th Mar 2015 7:49pm
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carrotbay



Member Since: 18 Aug 2013
Location: Northants, UK
Posts: 699

United Kingdom 2008 Defender 110 BMW M57 3.0 Diesel XS CSW Auto Santorini Black
Mine's been off a couple of times now. I've found it easier to do 2 bolts from above and the other 2 from underneath. 2008 Defender 110 XS SW - M57N2 / 6HP28X
Post #405605 8th Mar 2015 1:33pm
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nitram17



Member Since: 08 Jun 2014
Location: newcastle
Posts: 2261

custom90steve wrote:
Or get a tune with EGR delete, then you fit a solid blank and that's it forever.


Whats the pros and cons of a EGR valve?....what do you lose or gain if you remove it?(not interested in sound effects Laughing )
Post #405611 8th Mar 2015 1:58pm
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Jonno



Member Since: 06 Mar 2012
Location: Yorkshire
Posts: 234

United Kingdom 2011 Defender 90 Puma 2.4 HT Santorini Black
Thanks for all the replies, if it's not horrible weather on Monday I may try to do mine then and report back.

Jonno


Last edited by Jonno on 12th Mar 2015 6:58pm. Edited 1 time in total
Post #407000 12th Mar 2015 5:56pm
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K9F



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

United Kingdom 2008 Defender 90 Puma 2.4 XS CSW Stornoway Grey
nitram17 wrote:
Whats the pros and cons of a EGR valve?....what do you lose or gain if you remove it?(not interested in sound effects Laughing )


Here you go......

dgardel wrote:
Basically for reduce the NOx (generated by the temperature and NOT by the type of fuel).

On the gasoline engines NOx are trapped by the 3-way cat. Diesel engine (that uses 2-way cat because the temperatures are too low for a 3-way) need the EGR for reduce the NOx, but you reduce the O2 inside the combustion chamber (= less combustion efficiency).

So if you close the EGR (by ECU -contact Bell Auto Services here) the engine run a lot better with, yes, a little bit more NOx, but with low HC, CO and Particulate emissions.

AND, the EGR part of exhaust gas (with soot) ant the oil vapor recirculation produce a blck nud tha, during the miles, blocks the inlet manifold.




Click image to enlarge


If you want, try to remove the temp sensor on our Puma inlet manifold and see what......................

When combustion temperatures exceed 2500 degree F., atmospheric nitrogen begins to react with oxygen during combustion. The result is various compounds called nitrogen oxides (NOX), which play a major role in urban air pollution. To reduce the formation of NOX, combustion temperatures must be kept below the NOX threshold. This is done by recirculating a small amount of exhaust through the "exhaust gas recirculation," or EGR. valve.

In modern diesel engines, the EGR gas is cooled through a heat exchanger to allow the introduction of a greater mass of recirculated gas. Unlike SI engines, diesels are not limited by the need for a contiguous flamefront; furthermore, since diesels always operate with excess air, they benefit from EGR rates as high as 50% (at idle, where there is otherwise a very large amount of excess air) in controlling NOx emissions.

Since diesel engines are unthrottled, EGR does not lower throttling losses in the way that it does for SI engines (see above). However, exhaust gas (largely carbon dioxide and water vapour) has a higher specific heat than air, and so it still serves to lower peak combustion temperatures; this aids the diesel engine's efficiency by reduced heat rejection and dissociation. There are trade offs however. Adding EGR to a diesel reduces the specific heat ratio of the combustion gases in the power stroke. This reduces the amount of power that can be extracted by the piston. EGR also tends to reduce the amount of fuel burned in the power stroke. This is evident by the increase in particulate emissions that corresponds to an increase in EGR. Particulate matter (mainly carbon) that is not burned in the power stroke is wasted energy. Stricter regulations on particulate matter (PM) call for further emission controls to be introduced to compensate for the PM emissions introduced by EGR.

The most common is particulate filters in the exhaust system that result in reduced fuel efficiency. Since EGR increases the amount of PM that must be dealt with and reduces the exhaust gas temperatures and available oxygen these filters need to function properly to burn off soot, automakers have had to consider injecting fuel and air directly into the exhaust system to keep these filters from plugging up.
.


p.s. my Defender run from new with the EGR closed!!!! Now it has 83000kms
 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!!
Post #407016 12th Mar 2015 6:41pm
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nitram17



Member Since: 08 Jun 2014
Location: newcastle
Posts: 2261

Thanks K9 great answer as always Thumbs Up
Post #407076 12th Mar 2015 9:41pm
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