EGR Mishap!!!!

richy_335d · 05-10-2016, 11:07 AM

After replacing a faulty injector a few weeks ago I decided to take the opportunity to do some preventative maintenance whilst the intake manifold was off.

Replaced all glow plugs along with the relay
Replaced EGR Stat and Main Stat
Removed Swirlflaps and fitted PMW blanks along with new seals
Replaced all vacuum hoses for 3mm Silicone ones
and cleaning the intake manifold out along with the EGR valve. I was pushing the valve seat in and out to check it moved and I slipped and a piece broke off, see top left pic. I checked that it was still seated which it was and so thought it would work ok without it. How wrong was I!!!

After a few days of driving without problem one morning it came up with high emissions error and intake temp sensor error and stalled. Couldn't get it to go so stripped egr valve out to find the valve seat completely missing, approx 30mm in diameter. Luckily I found it in the intake manifold but it could have easily made it's way into the engine!!!!

Anyway I've made a blank and fitted it to the egr valve, seen a few people using 22mm compression plugs but as you can see in the bottom right mine is a lot larger so creates a better seal with no risk of being drawn into the engine.

Took it out for a spirited drive today and no errors whatsoever, so my question is will it do any harm driving around with it blanked off without having it coded out?

Thanks

Aragorn30d · 05-10-2016, 12:09 PM

remove the lot!

Bin the cooler and its troublesome thermostat, blank the manifold and replace the EGR valve with a delete kit.

As for your question, after a few miles you'll get an engine light and fault codes will appear saying the EGR isnt working if you've blanked it off without mapping it out.

If the car is already mapped, some tuners disable it without you asking, so it might already be fine.

richy_335d · 05-10-2016, 12:38 PM

The car does feel very responsive anyway so thinking it may have been mapped out. Was monitoring the load % for
Egr valve on I Carly and it was 80% on low throttle down to 5 on full throttle. Would expect this to be zero if it had been coded out. Will look at cooler removal. Take it you have to by a coupling to join the water hoses together after removing the cooler

Aragorn30d · 05-11-2016, 10:33 AM

no, just blank the water hoses. 18mm silicone end cap IIRC is what you need. Theres a guy on ebay that does the manifold blank too, and i think allard does a nice piece to replace the EGR valve itself.

richy_335d · 05-11-2016, 12:19 PM

Thanks mate. Big help. Am I at risk of blocking up dpf through not regenerating as much due to the intake temperatures being cooler?

05-10-2016, 11:07 AM	#1
richy_335d Private First Class 11 Rep 121 Posts Drives: e91 335d m sport Join Date: Feb 2010 Location: wrexham, north wales, uk iTrader: (1)	EGR Mishap!!!! After replacing a faulty injector a few weeks ago I decided to take the opportunity to do some preventative maintenance whilst the intake manifold was off. Replaced all glow plugs along with the relay Replaced EGR Stat and Main Stat Removed Swirlflaps and fitted PMW blanks along with new seals Replaced all vacuum hoses for 3mm Silicone ones and cleaning the intake manifold out along with the EGR valve. I was pushing the valve seat in and out to check it moved and I slipped and a piece broke off, see top left pic. I checked that it was still seated which it was and so thought it would work ok without it. How wrong was I!!! After a few days of driving without problem one morning it came up with high emissions error and intake temp sensor error and stalled. Couldn't get it to go so stripped egr valve out to find the valve seat completely missing, approx 30mm in diameter. Luckily I found it in the intake manifold but it could have easily made it's way into the engine!!!! Anyway I've made a blank and fitted it to the egr valve, seen a few people using 22mm compression plugs but as you can see in the bottom right mine is a lot larger so creates a better seal with no risk of being drawn into the engine. Took it out for a spirited drive today and no errors whatsoever, so my question is will it do any harm driving around with it blanked off without having it coded out? Thanks
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05-10-2016, 12:09 PM	#2
Aragorn30d Lieutenant Colonel 169 Rep 1,596 Posts Drives: E90 330d Join Date: Mar 2015 Location: Fife iTrader: (0)	remove the lot! Bin the cooler and its troublesome thermostat, blank the manifold and replace the EGR valve with a delete kit. As for your question, after a few miles you'll get an engine light and fault codes will appear saying the EGR isnt working if you've blanked it off without mapping it out. If the car is already mapped, some tuners disable it without you asking, so it might already be fine.
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05-10-2016, 12:38 PM	#3
richy_335d Private First Class 11 Rep 121 Posts Drives: e91 335d m sport Join Date: Feb 2010 Location: wrexham, north wales, uk iTrader: (1)	The car does feel very responsive anyway so thinking it may have been mapped out. Was monitoring the load % for Egr valve on I Carly and it was 80% on low throttle down to 5 on full throttle. Would expect this to be zero if it had been coded out. Will look at cooler removal. Take it you have to by a coupling to join the water hoses together after removing the cooler
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05-11-2016, 10:33 AM	#4
Aragorn30d Lieutenant Colonel 169 Rep 1,596 Posts Drives: E90 330d Join Date: Mar 2015 Location: Fife iTrader: (0)	no, just blank the water hoses. 18mm silicone end cap IIRC is what you need. Theres a guy on ebay that does the manifold blank too, and i think allard does a nice piece to replace the EGR valve itself.
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05-11-2016, 12:19 PM	#5
richy_335d Private First Class 11 Rep 121 Posts Drives: e91 335d m sport Join Date: Feb 2010 Location: wrexham, north wales, uk iTrader: (1)	Thanks mate. Big help. Am I at risk of blocking up dpf through not regenerating as much due to the intake temperatures being cooler?
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