 | Home > Puma (Tdci) > EGR valve removal for cleaning |
 
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| AlexSmith Member Since: 05 Sep 2013 Location: Arroio do Meio, RS Posts: 47   
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First of all, I know there is a post with similar subject and really lots of useful information (http://www.defender2.net/forum/topic2227-150.html).
I just followed many of the information found there and got my EGR removed, cleaned and refit at home, with no major tools needed. So let me start with the tools I used:  Click image to enlarge Click image to enlarge Click image to enlarge So basically one 8mm and one 10mm sockets (yes, they managed to use 2 different screws on the valve.) With the tools in hands, I must say the effort needed in order to remove the screws was incredible high. The place where the valve lies is really narrow to get, specially because I don't have small hands. Expect some scratches on your skin if you plan to do it yourself. 
Also, standing on the top of the engine is very tiring. I had to be careful to avoid stepping on the wrong place and bending or damaging something. I found much easier to get to the EGR by using an alternative way of keeping the bonnet opened, using some elastics instead of the standard bonnet holder. Click image to enlarge Click image to enlarge In the following pictures, I try to make it easier for you to locate the EGR and its screws (there are two on each gasket, in a total of four screws). From the top of the engine: Click image to enlarge Click image to enlarge From underneath the vehicle: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Here you can see the tools hooked up to the screws: Click image to enlarge Once I was able to unscrew the screws, I also had trouble with one of the gaskets falling in a nearly impossible to reach corner of the engine. I had to use a long and hard wire to get the gasket back to my hands, not before spending more than one hour trying to locate it. Good news is that this is the worst part of the job. Once you have the valve in your hands, it became a simple cleaning job, which I did using mainly WD-40. And, after a couple hours, here's the EGR removed. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge The EGR dirt was noticeable, as well as the loud noise it did on the 'self-cleaning' stage, when I turned off the engine. Besides cleaning, I also disassembled the EGR to understand its inner workings. Here are some pictures: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge I read some people used to remove the central gear in order to keep the EGR always closed. Some people from South Africa reported they don't even get the MIL turned on by doing so, but I decided to just clean the EGR and refit it. I'll wait until I do a remap to have it turned off on the ECU. The refitting job was fairly easy, now I knew how to get to the screws. Just had to be very careful with the gaskets, as I mentioned. After putting all back in place, the EGR noise was simply gone (ok, I'm still able to hear the valve operating on the self-cleaning stage, but the noise is incredible low now). I'm very happy with the results up to now and hope this post can be useful to someone else. 2020: Defender 110 SW 300 Tdi 2004 Alpine White 2013-2017: Defender 110 S 2.4 (Puma) 2008 Stornoway Gray 2002-2005: Defender 90 CSW 300 Tdi Dark Green |
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14th Sep 2015 2:50pm |
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| theorangebandit Member Since: 03 Jun 2013 Location: Stowmarket Posts: 862 |
Noticed how you bungeed the bonnet. Have you now got two dents in the bulge ?
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14th Sep 2015 3:57pm |
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| AlexSmith Member Since: 05 Sep 2013 Location: Arroio do Meio, RS Posts: 47
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Yes, that's what I heard. And I tried it here (my Defender is MY2008, but also a Puma 2.4), but after exactly three starts, MIL turned on and those common faults showed up in the scanner.  2020: Defender 110 SW 300 Tdi 2004 Alpine White
2013-2017: Defender 110 S 2.4 (Puma) 2008 Stornoway Gray 2002-2005: Defender 90 CSW 300 Tdi Dark Green |
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14th Sep 2015 5:01pm |
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| AlexSmith Member Since: 05 Sep 2013 Location: Arroio do Meio, RS Posts: 47
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You mean some damage to the painting due to the wipers end touching the bonnet? Fortunately not, because I used two not-very-strong elastics, one on each side, and I cared to avoid too much pressure. I did a small crack on one of the wiper bolt cover ("plastic nut cap" on the picture below) the last time I opened the bonnet that much. Didn't know that could happen by that time. 2020: Defender 110 SW 300 Tdi 2004 Alpine White
2013-2017: Defender 110 S 2.4 (Puma) 2008 Stornoway Gray 2002-2005: Defender 90 CSW 300 Tdi Dark Green |
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14th Sep 2015 5:05pm |
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| theorangebandit Member Since: 03 Jun 2013 Location: Stowmarket Posts: 862 |
I've cracked one of mine too, hasn't caused any issues. I have two tiny dents as I'm used to being able to throw the bonnet right up and bungee securely. Before I owned a puma I had never worked on a puma. Lesson learned. I now simply remove the bonnet when needing the space.
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14th Sep 2015 5:13pm |
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| Supacat Member Since: 16 Oct 2012 Location: West Yorkshire Posts: 11018  
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Haven't looked for the thread but wasn't there a TSB about removing the engine lift bracket?
Click image to enlarge |
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15th Sep 2015 4:40pm |
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| theorangebandit Member Since: 03 Jun 2013 Location: Stowmarket Posts: 862 |
The advise for the engine hoist bracket was to either remove or to check the bolts are tight. It is common for them to rattle loose and cause an irritating rattle when engine is running. And possibly chaff on pipes and cables in the area. Mine was already removed haha
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15th Sep 2015 4:55pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20446
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Glad my EGR is effectively dead by remap.
Anyone know the torque for the hoist / lift bracket? |
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15th Sep 2015 6:26pm |
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| Primaryroo Member Since: 15 Aug 2020 Location: kent Posts: 21  
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Hi guys just taking off egr..... No dramas but on close inspection and looking at removing the center gear. The shaft that is connected to the egr blanking bit retracts and extends.... And in the black lid there is a movable sensor where the top of the shaft sits...... Would this throw up a fault as it seems to make contact and therefor would give an anologe guide to the computer or am I over complicating the sensor 🤔 series 2a 1966
defender 90 1991 discovery 3 2005 discovery 2 2003 defender puma 110 2008 defender puma ex scottish power 2.4 2011 |
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7th Oct 2020 5:31pm |
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| AlexSmith Member Since: 05 Sep 2013 Location: Arroio do Meio, RS Posts: 47
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From my experience, everything I tried (unplugging, using the blank-plate or removing the central gear) made the Check Engine light come up and EGR faults to show up in the scanner. But many people from South Africa report they did it without any issues... Perhaps they have a different map file in their ECU? I really don't know. 2020: Defender 110 SW 300 Tdi 2004 Alpine White
2013-2017: Defender 110 S 2.4 (Puma) 2008 Stornoway Gray 2002-2005: Defender 90 CSW 300 Tdi Dark Green |
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7th Oct 2020 6:28pm |
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| MartinK Member Since: 02 Mar 2011 Location: Silverdale (Lancashire/Cumbria Border) Posts: 2665 
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Great thread - should be stickied
Defender "Puma" 2.4 110 County Utility (possibly the last of the 2.4's) |
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8th Oct 2020 12:13pm |
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| sikDefender Member Since: 22 Jul 2020 Location: 2447 Posts: 8  
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nice thread. thanks for this mate.
I'm about to take this little job on this weekend - 2.4 Puma 2010 quick question - I got the little resistor EGR bypass mod off eBay too . . . anyone tried this one out? link below: https://www.ebay.com.au/itm/162562040332?h...Swcj5ZSz9Z if somethings hard to do, its not worth doing - Homer *just jokes... try it till you break something |
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19th Jul 2021 11:48am |
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| swt Member Since: 24 Aug 2018 Location: Cumbria Posts: 163 
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SikDefender- did you try the resistor mod?
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4th Aug 2021 7:27am |
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| AlexSmith Member Since: 05 Sep 2013 Location: Arroio do Meio, RS Posts: 47
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I'd like to know that too. Don't see why it would not work. Unless there are other sensors controlling the gases flow besides the EGR's parking points (MAF, maybe?). Otherwise the EGR valve itself would work as a blank plate. Sounds good. But let's hear from @sikDefender. 2020: Defender 110 SW 300 Tdi 2004 Alpine White
2013-2017: Defender 110 S 2.4 (Puma) 2008 Stornoway Gray 2002-2005: Defender 90 CSW 300 Tdi Dark Green |
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23rd Oct 2021 9:28pm |
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