Removed EGR entirely today

ChrisEm · Post by **ChrisEm** » Sun Jul 01, 2007 11:08 pm

After having trawled the various posts on EGR fors and againsts I went the whole hog and stripped it out today.
Similar to the apparatus that Nick Skidmore produces I manufactured my own from all the existing parts. I have removed all the EGR parts with the exception of the wiring loom. I have retained the EGR valve and solenoids in case it causes any problems with the electrickery circuits.
I removed the long pipe above the inlet manifold and sawed off the flange that mounts to the manifold. I then filled the hole in the flange with weld to produce a blanking plate and refitted the flange to the inlet manifold.
I removed the pipe from the manifold and cut through it to retrieve the fitting that screws into the manifold. This fitting I then filled with weld to produce a blanking plug for the manifold. Some of you may think I'm daft for hacking the original system apart in case I wish to refit it in the future, however I can re instate the system in the future if required.I would have liked to clean the inlet manifold but had to reassemble the system as my wife needs the motor tomorrow.As far as performance goes it may be psychosomatic but it does seem a little perkier. I have not noticed any adverse symptoms by disconnecting the electrical or any other parts of the EGR system. I will monitor the performance and repost if there is any change.

bigdaddycain · Post by **bigdaddycain** » Mon Jul 02, 2007 3:00 am

Thanks Chris em,i await your findings.

I have been following this E.G.R saga over the years, and i'm leaning towards blanking the E.G.R. system completely,as its my understanding that the system is effective when new,then performance falls off during the years, ultimately sludging the inlet manifold with gunge.

RobnKathryn · Post by **RobnKathryn** » Mon Jul 02, 2007 10:14 am

If your inlet manifold is anything like mine it will be like this!!!
I disabled egr 6 months ago.....not complete removal but blanked at the vacuum pipe and inlet manifold. It hasn't mad eany difference to fuel usage, but performance has been smoother and a bit more responsive.

Rob[/quote]

bigdaddycain · Post by **bigdaddycain** » Mon Jul 02, 2007 10:30 am

Thats interesting RobnKathryn... Ive heard they sludge up but DAMN!

I had no idea they could get that bad! How did you clean it all out? A paraffin bath or something similar?

Have you been tempted to remove the inlet manifold to check its remaining clear after the E.G.R. removal?

Have you any tips for the best way to disable? I'm very interested in this subject,and on one hand i want to remove mine,but on the other hand,something deep down in my head is telling e NOT to remove something that mazda / ford deemed neccessary to fit in the first place.

I understand its for an emmisions issue that doesn't apply as strictly in the UK,but considering my bongo flew through the emissions test on its recent mot, (second rev of five

) I dont want to potentially fixing some thing that aint broke!...OOh, what should i do?

RobnKathryn · Post by **RobnKathryn** » Mon Jul 02, 2007 11:43 am

Hi, I blanked egr off at the point where egr pipe joins the inlet manifold with a 20 Euro Cents coin.....also blocked vacuum tube as per Veg_Ian's method.

I think the best collection of info and debate on this subject is in this tread:

http://www.igmaynard.co.uk/bongo/forum/ ... old+sludge

Yes I've been tempted to check the manifold again, but it's quite a job so I haven't done it!

One thing I noticed is that the winter pack cold start switch no longer has any effect, so I guess that this functioned by sending warm exhaust gas to the inlet manifold via the egr system. Perhaps if this was widely used in my vans early days in Japan, then that may account for the state of my manifold as I would guess that there is a lot more crap, in exhaust gas when the engine has just been started from cold than when it is warm. Don't know if this is the case, but it seems logical to me.

Having experienced van with egr and without, I wouldn't loose too much sleep about whether to do it or not, it doesn't make enough difference to worry about. If you use the method I have then it's reversable easily.........but either way.....your van isn't going to die if you don't do it, nor is it going to die if you do it!

Rob

smartmonkey · Post by **smartmonkey** » Mon Jul 02, 2007 12:46 pm

I would expect that amount of gunge on any diesel with an EGR. Even the latest VW TDi's look like that after 50,000 miles.

bigdaddycain · Post by **bigdaddycain** » Mon Jul 02, 2007 12:58 pm

Right!... Thanks for the advice chaps

Chin · Post by **Chin** » Fri Jul 06, 2007 10:35 am

I have notice that my 1st air intake manifold now leaking motor oil, it used to have a lot of sludge. I had blocked the vaccum solenoid as instructed in some other post. Just wonder if the motor oil that leak out is from the exhaust manifold return pipe or from the engine itself. Any other people having the same problem? Will it cause serious problem?

phil 1 · Post by **phil 1** » Fri Jul 06, 2007 2:53 pm

Chin wrote:I have notice that my 1st air intake manifold now leaking motor oil, it used to have a lot of sludge. I had blocked the vaccum solenoid as instructed in some other post. Just wonder if the motor oil that leak out is from the exhaust manifold return pipe or from the engine itself. Any other people having the same problem? Will it cause serious problem?

Hi i have blocked the vacuum pipe and i have noticed some oily black stuff leaking around 1st and last intake. I assume its some of the sludge thats built up in the manifold not noticed any other problems.